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)

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).

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

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.