Stick Welding Basics & Techniques | A Beginner’s Guide

Stick Welding Basics: Techniques and Tips for Beginners

Introduction: The Versatile Arc

Stick welding, officially known as Shielded Metal Arc Welding (SMAW), is one of the most versatile and widely used welding processes in the world. Loved for its simplicity, portability, and ability to work outdoors and on dirty or rusty metal, it’s the go-to method for construction, farming, repair work, and pipeline welding.

While it’s relatively easy to start, mastering Stick welding takes practice. This guide will walk you through the fundamentals—from setting up your machine to running your first bead—and provide pro tips to help you build confidence and skill.

⚠️ Safety First! Always wear an ANSI Z87.1 certified welding helmet, fire-resistant jacket and gloves, safety glasses, and sturdy boots. Work in a well-ventilated area and keep a fire extinguisher nearby.

Part 1: The Basics – How Stick Welding Works

Stick welding uses an electric circuit that runs from the welder, through an electrode (the “stick”), across the arc, into the workpiece, and back to the welder via a ground clamp.

• The Electrode: The consumable “stick” is a metal rod coated in a material called flux.

• The Arc: When you strike the electrode against the workpiece, it creates a super-hot arc (~6,500°F / 3,600°C) that melts the base metal and the tip of the electrode.

• The Flux: The coating melts, creating a shielding gas that protects the molten weld pool from atmospheric contamination (oxygen and nitrogen). It also forms a slag layer over the cooling weld, which must be chipped away.

🖼️ IMAGE: [stick-welding-process-diagram.png]
Alt-text: Diagram showing the Stick Welding (SMAW) process, illustrating the electrode, arc, weld pool, shielding gas, and slag.

Part 2: Essential Gear & Machine Setup

Gear Checklist:

• Welding Machine (AC, DC, or AC/DC)

• Electrode Holder & Ground Clamp

• Welding Cables

• Electrodes (Rods): See chart below.

• Helmet, Gloves, Jacket

• Chipping Hammer & Wire Brush

Machine Setup in 3 Steps:

1. Select Polarity:

   • DCEN (Direct Current Electrode Negative): The electrode is negative, the workpiece is positive. Faster melt-off, less penetration. Good for thin metals.

   • DCEP (Direct Current Electrode Positive): The electrode is positive, the workpiece is negative. Deeper penetration. This is the most common setting for Stick welding.

   • AC (Alternating Current): Used for specific rods (like 7018AC) or when using an AC-only machine.

2. Choose Your Electrode:
   The rod number (e.g., E7018) tells you everything:

   • E: Electrode

   • 70: Tensile Strength (70,000 psi)

   • 1: Welding Positions (1=All, 2=Flat/Horizontal, 4=Overhead & Vertical)

   • 8: Flux Coating & Current Type

   🖼️ IMAGE: [common-welding-rods-comparison-chart.jpg]
   Alt-text: A visual comparison chart of common welding rods: 6010, 6011, 6013, 7018, and 7024, showing their characteristics and best uses.

   Rod Type	Key Features	Best For	Polarity
   E6010/6011	Deep penetration, works on dirty/rusty metal	Pipeline, root passes, poor fit-up	DCEP (6010), AC/DCEP (6011)
   E6013	Easy to use, smooth arc, light penetration	Beginners, sheet metal, clean steel	AC/DCEN
   E7018	Low-hydrogen, strong, high-quality weld	Structural steel, critical welds	DCEP (AC for 7018AC)
   E7024	Fast deposition, smooth finish	High-speed flat fillets	AC/DCEP

3. Set the Amperage:

   • A good starting point is 1 amp for every 0.001 inch of material thickness.

   • Example: For 1/8″ (0.125″) steel, start at 125 amps.

   • Listen and Adjust: A good arc has a crisp “bacon sizzle” sound. If it crackles and sputters, the amps are too low. If it’s loud and violent, they’re too high.

Part 3: Core Techniques – Running Your First Bead

1. Striking the Arc

• Scratch Start: Like striking a match. Gently scratch the rod tip on the workpiece until the arc establishes.

• Tap Start: Quickly tap the rod directly on the workpiece and pull back slightly.

• Pro Tip: If the rod sticks, quickly twist your wrist to break it free. If it won’t break, release the electrode holder.

2. Maintaining the Arc Length

• This is the #1 most critical skill.

• Maintain a distance equal to the diameter of the rod’s metal core (“the wire”).

• Too long: Arc will flutter, creating a wide, porous, uneven bead.

• Too short: Rod will stick constantly and create excessive spatter.

3. Manipulating the Electrode

You control three things at once:

• Travel Speed: Move at a steady pace so the arc melts the base metal and fills the crater behind it. Too fast = skinny, ropey bead. Too slow = wide, piled-up bead.

• Work Angle: For a flat butt joint, hold the rod at a 90-degree angle from the workpiece.

• Travel Angle: For a flat bead, use a 5 to 15-degree drag angle (pointing back toward the finished weld).

🖼️ IMAGE: [stick-welding-travel-angle-diagram.jpg]
Alt-text: *Diagram illustrating the correct 5-15 degree drag angle for Stick welding, showing the electrode pointing in the direction of travel.*

Part 4: Pro Tips for Better Welds

• Clean Your Metal: While Stick can handle dirt better than other processes, clean metal will always give you a cleaner, stronger weld with fewer defects. Use a grinder or wire brush.

• Watch the Puddle, Not the Arc: The molten weld puddle tells you everything. It should be a consistent, fluid oval shape moving evenly along your joint.

• Control Heat with a Whip Motion: For thin metal or to prevent burn-through, use a slight “whipping” motion. Move the arc forward onto the leading edge of the puddle, then back slightly, then forward again.

• Avoid Long Arcs: Never “stretch” the arc to see the puddle better. This introduces contamination and ruins the weld.

• Practice, Practice, Practice: Get a box of 6013 or 7018 rods and a pile of scrap steel. Run beads in the flat position until maintaining a consistent arc length and travel speed becomes second nature.

🖼️ IMAGE: [good-vs-bad-stick-weld-beads.jpg]
Alt-text: Side-by-side photos of a good, consistent Stick weld bead versus bad beads showing issues like undercut, porosity, and inconsistent travel speed.

Part 5: Common Problems & Quick Fixes

Conclusion: Your Journey Starts Now

Stick welding is a foundational skill that empowers you to build and repair almost anything made of steel. It rewards patience and practice. Don’t get discouraged by stuck rods or ugly beads at first—every welder has been there.

Grab your hood, fire up your machine, and start laying beads. The muscle memory you build is the key to unlocking the craft.

Ready for the Next Step?

• Shop Stick Welding Machines

• Browse Welding Rods & Consumables

• Learn Advanced Stick Welding Techniques

External Link: For incredible visual tutorials and advanced techniques, watch the videos from Welding Tips and Tricks.