Shielded arc welding is a process for making permanent joints. Also called “stick welding” it is the most common method of obtaining permanent joints of different metals in a weld pool using electric current and anodes.
Due to its flexibility and ease of use, this method is becoming increasingly popular. An anode is a welding wire in the form of a carbide rod (hence the name) which is surrounded by a coating of metal powders or composites with a bonding agent to ensure their adhesion to the surface.
What is shielded metal arc welding?
Another name for this technology is “GMAW”. This is where the bare electrode is used. It is fed continuously into the weld pool.
How the process works: welding is performed by means of an electric arc burning between the end of the welding wire and the metal to be welded under a layer of flux coating. When the electrode melts, it becomes part of the weld.
What happens after the manual metal arc welding: the molten metal layer acts as a protective environment during the curing process – this creates protection so that oxygen and steam, as well as impurities such as water, do not interfere with the quality of the welding process.
Bottom line: the result is a liquid metal joint between the metal electrode and the workpiece, called a weld pool (this is the area of the weld in the metal workpiece where the base metal is at the welding point and is penetrated by the filler metal).
A manual arc welding kit includes two cables (wires). One of them has an electrode holder on the end, and the other one has a terminal designed for connection to the wire that connects the minus terminal of the electric arc element with the body of the product in which it is installed.
How the welding process is carried out:
- The first step is to close the circuit. To do this, the consumable electrode must come into contact with the base metal.
- Second step: the electrode must be withdrawn to start a steady electrical discharge (arc). The resulting region of very high temperature contributes to the melting of the consumable electrode itself along with the metal. As a result part of the electrode fuses with the base metal.
- Third step: the manual metal arc welding process will use shielding gases or fluxes to eliminate the negative effects of air on the process.
Slag is a byproduct formed during arc welding to protect your workpiece. The molten metal slag is removed once it has completely solidified – a welding bevel must remain underneath.
Flux-shielded arc welding processes
Flux-cored arc welders began to spread in the mid-sixties.
- This welding technique replaced shielded metal arc welding. The positive quality of the new process is that it does not require the electrodes used in SMAW, which overcomes most of the limitations.
- Flux-cored arc welding (FCAW) is an auto or half-automatic welding process.
- A continuous-feed tubular electrode including flux and DC welding power supply is used here.
- The arc is ignited from the electrode at a specific location where the work is performed.
- During welding, the electrode melts, and the included flux protects the place where the stick welder is carried out from atmospheric contamination or negative influences.
Tungsten gas arc welding
TIG welding is properly called gas tungsten arc welding (GTAW). This is the name most European and American weld material manufacturers use when repairing stick welders in their procedures.
As GTAW welding emerged in the 1940s, it used helium as the main shielding gas, and the term “helium welding” used to be common, so if you’re about to repair old equipment from an old drawing, the term may come across to you – arc welders, beware!
The features of the GTAW (TIG) welding
Hand welding with tungsten gas is a complicated method because the welder needs to coordinate all actions. Two hands must be involved in the work, as in torch welding, because most often the manual welder simultaneously feeds the filler material to the weld area and at the same time applies the torch. It is necessary to control the arc – it should not be long, and the electrode should not touch the workpiece.
The peculiarity of this type is the way the arc is formed and the addition of filler material.
The GTAW welding method is the most difficult because of the need to use both hands, but it is versatile when it comes to welding metals of different origins. Although slow, this method provides the best quality welds when done correctly. It is usually used for critical welds and for working with metals other than ordinary steel. And it is suitable for tasks requiring precise and welds thinner metals.
Features of MIG welding
MIG welders use a special tool called a “spool gun” in their work. An electrode in the form of a spool of wire is fed through it.
Other features:
- Suitable metals: Steel, aluminum, stainless steel;
- MIG welding provides good welds;
- Used for joining thinner metals with a good finish and the least risk of burning;
- But there are disadvantages: not suitable for thick metals.
The workpiece and the electrode melts forming a pool of molten metal as in the above types.
Is Stick Welding AC or DC?
Currents – alternating current (AC) or direct current (DC) are used in stick welding. But direct current is recommended for the latter. This is because it has a number of advantages, such as easier overhead welding, a better arc blow, and less welding spatter.
Electric current is used to create an arc of various arc length. This process takes place directly between the parts to be welded and the electrode. The place where these parts have been joined using this technique is called the weld pool.
DCEP or DCEN?
Setting up the manual arc welding process on the unit is a necessary step for operation in DCEP or DCEN mode.
The machine contains 2 types of contacts: “+” and “-“, to which the welder connects the stick welder and the earth clamp. In this case, it is necessary to understand which contact to connect to.
For example, if the welding stick is connected to the plus terminal and the clamp to the minus terminal, it means that welding is carried out with an electrode with a “+” sign (DCEP) and it is positive. In the other case the electrode is “-“, i.e. negative, and its abbreviation is DCEN.
| DCEP | DCEN |
| This abbreviation means, as described above, an electrode charged positively, but a welding object charged negatively. | This abbreviation means when the electrode unit is minus and the welding object is plus. |
| The electric current flows away from the “-” to the “+” which means a flow of current must always go from the object to be welded towards the electrode. | This is the case when the alternating current flows away of the electrode to the object being welded. |
| This leads to intense heating and further intrusion into the workpiece. | DCEN the current is less concentrated, so it penetrates less and the heating of the metal is not as intense as with DCEP. |
We also recommend reading another article “How to hook up stick welding leads”, we think it will also interest you and you will find useful information on this topic.
Materials and applications
Stick welding is widely used to join various materials of steel and iron. It is used in a variety of applications:
- Repair and restoration;
- Industrial areas, such as joining pipelines;
- Work with various parts in the workshop;
- The sphere of construction objects – massive, heavy steel structures, in which the basis is steel.
Gas-arc welding is most often used in repair and maintenance applications, primarily because of its versatility and ease of use.
Materials on which stick welding in a shielding gas environment is possible:
- nickel;
- aluminum;
- malleable cast iron;
- stainless steel;
- cast iron;
- copper;
- steel (carbon steel, high grade, and low grade).
Not really applicable to non-ferrous metals. But it can be used for nickel, copper, and even aluminum.
Stick welding equipment and features
There is a widespread belief that stick welding is the easiest and simplest welding process – this is a fact. The entire job can be done in a very short period of time. The equipment and installation used are simple and not time-consuming.
All the equipment consists of four components: the welder, the DC power source, the electrode holder (also used as a rod holder), the ground clamp, and the contact welding electrode. This part should be used to create a specific arc length.
The interesting thing about this technique is that such a part of the weld as the “weld bead” is of different types: graphite, copper, and steel.
How much do stick welding machines cost?
It is not uncommon for contact welding to be priced differently depending on the type. The choice depends on what you want to use it for and what your budget is. You don’t need to spend a lot of money to meet your basic welding needs. Any machine with a spot-welding device will work for welding.
You should also look at the brand, warranty, and number of parts to be repaired. If you plan to do a lot of welding, a well-known brand is a good choice. The most popular brands in the world today are Miller, Lincoln Electric, and Hobart. For a replacement that will only be used occasionally, a cheap option will do.
Amperage for stick welding
It is generally accepted that a person with sufficient experience can weld successfully at one hundred and fifty amperes. In addition, you can make several passes to get the desired welding quality. However, the more amperes you use, the fewer passes you will need.
Although there is nothing wrong with multiple passes, this solution requires some skill on the part of the welding technique. The most important recommendation is to study the weld pattern and the maximum weld width for the type of material for which it is intended.
Keep in mind, however, that the diameter can vary. For example, you can weld thicker types of material and make more passes if you have the proper skills. It is also important to select the size of the welding rod (electrode diameter) for the desired thickness of the metal. If you plan to work with thicker rods, check with the manufacturer for the “welding current” value.
It is best to study the tables for welding rods and the maximum thickness of the material indicated there.
It is recommended that:
- analyze the tables;
- find out the maximum thickness of the metal for the rods (the values given may not be final, for example, if the material is outside the limits given in the table when it is too thick, in which case it may be enough to make several welding passes);
- see the wire size (electrode diameter) and the amperage corresponding to it.
Many novice arc welders have difficulty selecting the amperage value. This becomes more important if the scale is not calibrated or if the values have been erased.
Slag removal tools
A large amount of slag is produced during the welding process. To finished weld, the weld bevel must be cleaned. To do this, the welder must remove the slag with a special tool.
Finally, the cleaning process is completed by brushing the weld bead a wire brush. This also ensures the aesthetic appearance of the weld joint.
Following these steps will save time when performing the action called “laying weld”.
Safety Precautions
An important tip when using stick welding is safety precautions.
Protective equipment is one of the most important elements of this type of work. Failure to do so can result in serious injury or even death.
To ensure safety when welding, you must protect your eyes, head, and body from exposure to radiation.
What you need to have with you:
- Protective or flame-resistant clothing with long sleeves to protect against ultraviolet light, sparks, slag, and metal spatter.
- Welding helmet with goggles to protect head and eyes (loss of vision from welding is among the most serious injuries in this type of work).
- If you are working in an enclosed area, you need to ensure good ventilation because of the hazardous gasses that are released: respirator or ventilation fan.
- When welding outdoors, be aware of your surroundings in any case.
Even though you wear proper protective equipment (also known as personal protective equipment – PPE), injuries from hot metal or sparks can cause your clothing to catch fire. The most common injuries, known as flashover, are caused by exposure to a welding stick. According to technical terms, a flash is ultraviolet radiation. It is similar to how a sunburn on a body part can cause cracks in a weld metal. That’s why it’s important to keep your body away from the equipment.
You should also be aware of your surroundings and work in well-ventilated areas.
Choosing the right electrode
What should you pay more attention in order not to make a mistake with the choice of a suitable option?
So, first, a little bit of information: there are over a million different arc welding electrodes available, but the most popular electrodes in this category remain those designed for welding mild steel.
To choose the right welding wire, you need to know what its marking means. The letters and numbers that mark the electrodes that make up a welding wire will help you do this.
Electrodes classified by the American Welding Society (AWS) as A5.1,(3) include various models marked (for example: E6010-6011 and E7014-7024).
How to decipher:
- The letter “E” simply means “electrode”.
- The first 2 digits indicate the strength of the additive metal. For example, model 7018 welding wire indicates that its tensile strength is 70,000 psi.
- As for the third digit in the sequence from left to right, it indicates the welding positions of the electrode. If the number here is 1, it indicates that the element can be used in various modes, creating vertical welding. The number 2 indicates that the element can only be used in the horizontal welding position of electrode.
- The fourth digit in the sequence indicates which flux is applied to the electrode and also indicates the current value under which an electrode can be used. The coating itself can include a variety of compounds. The main ones include iron powder, cellulose, calcium fluoride, and rutile.
The electrode material and its features
Let’s look at a few options:
| Rutile | They are easy to apply and provide a good appearance of the welds. There is a lot of hydrogen in the welds formed. They can crack. |
| Calcium fluoride | They form strong welds but have a rough, unsightly weld, convex appearance. |
| Cellulose | They are characterized weld penetration. Additional treatment is required to prevent cracking due to a large amount of moisture. |
| With iron powder | Provide fast filling of the joint (twice as fast as other materials). |
Aspects such as stopping time, polarity, and travel angle depend on the type of material. Those craftsmen who know how to weld with a rutile type electrode have great difficulty working with a cellulose element.
Usually, one of the 3 standard electrode types is used:
| E6010 | For working with low-grade and rusty metals. Deep penetration is provided with it. Welding in various positions is possible. |
| E6013 | For general, all-around welding. Gives fairly even welds. Sufficient penetration and easy to use. Beginner arc welders use this model. |
| E7018 | For quality metals. Designed to perform work in a variety of positions, this model is considered standard, while providing an attractive weld appearance. |
How to make the first weld correctly?
If everything is prepared, the first weld should be made. The most important check before igniting the arc is the setting. Make sure that the polarity matches the electrode. It is also a good idea to bring a piece of metal with you that can be used for the butt joint. Check all the settings. Next, use 2 scrap metal trim and butt them together.
Stick welding requires skill and some training, so it’s best to practice a little beforehand.
Choosing the angle
When welding with this method, the welder must consider the angle of travel.
There are the following welding methods with the corresponding angles (positions):
- The stick welding method used for flat, horizontal, and overhead welding is called the “dragging technique”. In this welding technology, the electrode core is held from the starting point in a direction strictly perpendicular to the weld and tilted upward at an angle of five to fifteen degrees.
- When welding in the vertical direction, a technique known as “front hand” is used. In this case, the angle of the welding wire is from zero to fifteen degrees (from a certain direction of movement).
Whatever the case may be in both cases, it is important that you try to change your body position and work angle to do a good job. Setting the correct angle will result in a perfect finish and quality weld. If defects occur, the option is a special shielding gas flooded over the hot weld.
Welding drawings sometimes show weld length and bevel angle as additional information to the welding symbols. For the welder, understanding the symbols is as important as learning how to weld correctly.
Advantages of Stick Welding
As a basic understanding of rod welding shows, this method has many advantages.
These include the following:
- Easy to learn: manual metal arc welding for beginners is easy to use.
- Outdoor work: the arc welding process is perfect for all types of outside works, since gas work is badly tolerated under windy circumstances.
- Flexibility: they may be used to stick weld a range of different thin materials and the unit is simple to handle.
- Transportability: a great soldering machine is easy to wear and carry. There is no need for additional gear such as a gas bottle or a wire reel.
- Affordability: the basic RTW machines are highly affordable.
- Easily removable: a fan is all you need to dispose of the welding fumes from welding, which is not possible with traditional MIG or TIG welding.
Be that as it may, stick arc welding under shielding gas is one of the most popular welding processes because of its versatility and ease of installation and handling. Although it is superior to other welding processes for maintenance or reconstruction, and despite the growing popularity of powder-coated arc welding, it continues to be widely used in heavy steel construction and manufacturing.
So we have given you detailed information about what is stick welding, but we want to provide you with one more video:
FAQ
What is the stick welding process?
It is a process that uses an electrode to create welds. The rod itself includes materials that release inert gases used to provide protection to the molten metal. Welding can be performed in a variety of positions on materials of any thickness.
Why is it called stick welding?
A welding machine (transformer), which generates an alternating current at an adjustable amperage, is used directly for stick welding. According to the documents of the Welding Society, this type of welding is shielded metal arc welding (SMAW), otherwise known as “Automatic submerged arc welding”.
A special rod, popularly called a “stick,” is used for welding. In professional terms, this is the process of electric arc welding. In this work, a constant electrical discharge (arc blow) is used as a heat source. It is needed, in particular, to transfer material from the filler rod (which is a wire with a diameter of 1-4 mm) to the weld.
This method differs from gas-flame welding, non-consumable electrodes welding, and so on in that a molten bath is formed, and filler metal is added from a single rod. When welding with wire, a welding converter is used, as mentioned above, and operates in the range of eighty to one hundred and fifty amperes.
What gas is used in stick welding?
Nitrogen, as well as neutral gasses fed to the fusible part of the base metal, are commonly used in stick welding. The welder uses electrodes connected to a high-current source to melt the metal component and the metal to be welded. When metals protected by a coating that turns into a liquid are fused together, resulting in a weld after cooling.
Active or inert shielding gases can be used in welding. They can also be mixed or combined with several inert gases. Triple combinations are possible.
What are the disadvantages of stick welding?
Once you get acquainted with how to work with contact welding, you will realize that this equipment has certain disadvantages. These include: Much more spatter and slag produced when welding. Not very easy to use on some thin metals. It requires a higher level of skill than the MIG process, which requires less experience to begin welding. Stick welding takes longer and is a much slower process compared to MIG welding, for example. This treatment is not suitable for reactive metals.
