Welding & Fabrication

Stick Welding

Stick welding, formally Shielded Metal Arc Welding (SMAW), is the original and most versatile portable welding process. Using flux-coated electrodes that create their own shielding gas and slag protection, stick welding works outdoors in wind and rain, on rusty or painted metal, and in positions inaccessible to other processes. Though it requires more cleanup and produces lower deposition rates than MIG, stick welding remains essential for construction, structural steel, pipeline, maintenance, and repair work. Every professional welder should master stick welding—it works when nothing else will and demonstrates fundamental arc welding skills that transfer to all other processes.

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Understanding Stick Welding

Stick welding creates an arc between a consumable electrode and the workpiece:

Process Characteristics:
- Self-Shielded: Flux coating produces shielding gas—no external gas required
- Slag Protection: Flux creates slag covering the weld, removed after cooling
- Portable: Simple equipment, no gas bottles
- Versatile: Works on dirty, rusty, painted surfaces (within limits)
- All Positions: Electrode formulations for every position

Equipment:
- Power Source: CC (constant current) AC, DC, or AC/DC machines
- Electrode Holder (Stinger): Holds electrode, conducts current
- Ground Clamp: Completes circuit to workpiece
- Electrodes: Various types and sizes for different applications

Polarity Options:
- DCEP (DC+): Electrode positive, deepest penetration, most common
- DCEN (DC-): Electrode negative, faster deposition, less penetration
- AC: Works with AC-rated electrodes, helps with arc blow

Common Electrodes:
- E6010: Deep penetration, DC only, pipe root passes
- E6011: Similar to 6010, runs on AC, field welding
- E6013: Easy to use, AC or DC, thin materials
- E7018: Low hydrogen, strongest, all-position structural
- E7024: High deposition, flat and horizontal only

Reading Electrode Classifications:
E7018 = E (electrode) 70 (70,000 psi tensile) 1 (all position) 8 (low hydrogen, DC+/AC)

Electrode Selection and Handling

Choosing and handling electrodes correctly is crucial:

E6010/E6011 - Cellulosic Electrodes:
- Fast-freeze slag for vertical/overhead
- Deep penetrating, forceful arc
- Excellent for dirty/rusty metal
- Creates rough bead appearance
- Used for: pipe roots, structural roots, field repair

E7018 - Low Hydrogen Electrode:
- Smooth, quiet arc
- High-quality, crack-resistant deposits
- Requires dry storage (rod oven)
- Most common structural electrode
- Used for: structural steel, pressure vessels, critical welds

E7024 - Iron Powder Electrode:
- High deposition rate
- Drag technique (electrode touches work)
- Flat and horizontal fillet only
- Fast, efficient production welding
- Used for: shipyard, fabrication shops

Electrode Storage:
Low-hydrogen electrodes (E7018, E7028) absorb moisture:
- Store in sealed containers or rod ovens
- Bake at 700-800°F if exposed to humidity
- Limit exposure time when removed from storage
- Moisture causes porosity and hydrogen cracking

Electrode Sizing:
| Material Thickness | Electrode Diameter |
|-------------------|-------------------|
| 1/8" (3mm) | 3/32" or 1/8" |
| 3/16" (5mm) | 1/8" or 5/32" |
| 1/4" (6mm) | 5/32" or 3/16" |
| 3/8"+ (10mm+) | 3/16" or larger |

Amperage approximately 1 amp per 0.001" of electrode diameter (varies by type).

Technique and Positions

Stick welding technique varies significantly by electrode and position:

Arc Length:
- Maintain arc length equal to electrode core diameter
- Too long: spatter, porosity, poor tie-in
- Too short: electrode sticks, rough bead, undercutting

Travel Speed:
- Watch the puddle, not the arc
- Slag should follow 1/2" to 3/4" behind the arc
- Too fast: narrow, ropy bead, undercut
- Too slow: excess buildup, cold lap, poor penetration

Electrode Angle:
- Work Angle: 90° for butt joints, 45° for fillets
- Travel Angle: 5-15° drag (pointing back toward completed weld)

Position Techniques:

Flat (1G/1F):
- Highest amperage range
- Straightforward technique
- Focus on travel speed consistency

Horizontal (2G/2F):
- Slight downward work angle
- Watch for undercut on top edge
- May need faster travel or lower amps

Vertical Up (3G/3F):
- Lower amperage
- Weave or whip technique
- Let puddle solidify between movements
- E6010/7018 work well

Overhead (4G/4F):
- Lowest amperage
- Keep tight arc length
- Faster travel prevents dripping
- E7018 slag helps support puddle

Pipe Welding:
- Combination of all positions in one joint
- 6G position: 45° fixed pipe—qualifies for all positions
- Root, hot pass, fill, cap with different techniques

Applications and Career Paths

Stick welding expertise is valued across industries:

Primary Applications:
- Structural Steel: Buildings, bridges, towers
- Pipeline: Cross-country pipelines, plant piping
- Shipbuilding: Hull construction, outfitting
- Construction: Field erection, modifications
- Maintenance/Repair: Equipment repair in any environment
- Heavy Equipment: Earth-moving equipment, mining, agriculture

Career Opportunities:

Construction Welder:
- Steel erection, bridges, infrastructure
- Travel to job sites
- Union and non-union paths
- $50,000-$80,000 depending on location

Pipeline Welder:
- Highest-paid welding specialty
- 6G certification required
- Travel extensively
- $70,000-$150,000+ with overtime

Boilermaker:
- Power plants, refineries, heavy industry
- Union trade with apprenticeship
- Combination of welding and fitting
- $60,000-$100,000

Maintenance Welder:
- Manufacturing plants, mines, utilities
- Repair and fabrication
- Stable location, benefits
- $45,000-$70,000

Ironworker:
- Structural steel erection
- Welding plus rigging and fitting
- Strong union presence
- $55,000-$90,000

Certifications:
- AWS D1.1 (Structural Steel)
- AWS D1.5 (Bridge Welding)
- API 1104 (Pipeline)
- ASME Section IX (Pressure Vessels)

Physical Demands:
Stick welding is physically challenging:
- Awkward positions
- Height work (structural, bridges)
- Outdoor conditions (heat, cold, wind)
- Heavy electrode boxes and equipment

Good physical condition extends career longevity.

Frequently Asked Questions

Why does my electrode keep sticking to the work?

Arc length too short, amperage too low, or starting technique issues. Try tapping (touch and lift) or scratching (like a match) to start. Increase amperage if the arc is hard to maintain. Keep electrodes dry—moisture increases sticking with low-hydrogen rods.

How do I prevent undercut when stick welding?

Undercut results from excessive heat or improper technique. Reduce amperage, slow travel speed (more fill), adjust electrode angle to direct metal into the toe, or use a weaving technique that pauses at the edges. Horizontal and overhead positions are most prone to undercut.

Can I stick weld stainless steel and aluminum?

Yes to stainless (with appropriate electrodes like E308L-16 or E309L-16), though TIG is preferred for quality. Aluminum stick welding is possible but rarely done—requires special electrodes, generates considerable spatter, and MIG/TIG are far superior. Stick excels on carbon steel.

Why is my E7018 weld porous?

Almost always moisture contamination. E7018 low-hydrogen electrodes must be stored dry (rod oven at 250-300°F) and used within hours of removal. Exposed electrodes can be re-dried at 700-800°F for one hour. Also check for contaminated base metal or improper technique (long arc).