Stick welding also known as Manual Metal Arc welding (MMA) is one of the oldest welding techniques and is still widely used in construction projects. It is a simple process in which a power source is used to create an electric arc between an electrode and metals to be joined.
An electrode is struck against the metal to ignite it, and then it is melted into the joint to create a weld. The flux on the weld metal serves as the slag that protects the weld from environmental contamination.
Whether you’re a seasoned welder or a curious beginner, this simple technique is best to start with.
History
The origin of stick welding dates back to the 1800s. In 1800, an inventor, Sir Humphry Davy, first developed an arc between two electrodes with the help of a battery. In the mid-1800s, welding using an arc was introduced.
French electrical engineer Auguste De Meritens used the heat of an arc to join two lead plates. Around 1900, British inventor Strohmenger advanced the welding technique by introducing a coated metal electrode.
He used a thin coating of clay to create a more stable arc. In 1914, Oscar Kjellberg introduced a stick-like coated electrode. He used iron wire pieces dipped in a thick mixture of carbonates and silicates to make the stick.
Stick Welding Machine Setup
Below, we have provided you with the machine setup of this manual metal arc welding technique.
1. Stick Electrodes
The first thing that comes to mind when considering this machine setup is sticking electrodes that match the parental metal. You also need to pick the size of the electrodes relevant to the thickness you want to weld.
Each electrode can be classified by a 4-digit stamp on the end, for example, E6013, E6010, E6011, and E7018. ‘E’ stands for electrode. The first two digits indicate the tensile strength, the third digit indicates the position in which the electrode is to be used, and the fourth digit indicates the type of flux coating and the current to be used.
2. Electrode Holder
This torch-like holder holds the electrode and conducts the electric current to it. There are two types of electrode holders- the square/twist lock holder and tongs.
The square/twist lock holder has a square opening that clamps electrodes into place when the head is twisted clockwise. On the other hand, tongs have grooves along the insides for the angle you want your electrode at.
These two types of holders work in the same way but only look different.
3. Polarity
You can perform manual metal arc welding in both positive and negative polarities. However, the required polarity is mentioned on the front of the box of electrodes.
- If the electrodes require AC/DC+ current, you need to attach the torch to the positive panel mount and the earth lamp to the negative panel mount.
- If AC/DC current is required, make sure to attach the earth clamp to the positive panel mount and the torch to the negative panel mount.
4. Settings and Amperage
You need to pick the right amperage to start welding. It will depend on how thick your electrode is. If the amperage is too high, the arc will be fierce with too much penetration.
On the other hand, if amperage is too low, the arc will be soft and fusion between the metals will be nearly possible.
How Stick Welding Works
The process involves creating an electric arc between a metal stick (electrode) and the workpiece, which melts both of them to form a weld pool. The intense heat from the arc causes the tip of the electrode to melt and deposit filler metal into the joint, bonding the metals together as the weld solidifies.
The flux plays a crucial role in the stick welding process. As the electrode melts, the flux decomposes and produces a shielding gas and a layer of slag. The shielding gas protects the molten weld pool from atmospheric contamination, such as oxygen and nitrogen.
Things You Should Consider Before Using Stick Welding Technique
Here are some things you should consider before using this welding technique.
- Before starting welding, you have to clean the metal surface to remove rust, dust, and other contaminants.
- You have to increase your travel speed and lower amps to keep the molten metal from dripping.
- While welding, you need to pull your weld. If you push, you will risk having slag trapped in the weld pool, leading to contamination.
- Your arc length should be shorter than your electrode diameter. For example, if you’re using a 2.6 mm electrode, your arc length shouldn’t be more than 3 mm.
- Make sure the electrode is not too close to or too far from the metal piece. If you pull the electrode too far, the arc will become unstable and produce more spatter.
- You don’t have to make a too-long arc. A long arc will affect the quality of your weld.
Pros and Cons of Stick Welding
Pros | Cons |
No separate shielding gas required | Controlling the arc length, angle, and movement can be challenging |
It is more portable and easier to set up compared to other welding systems | Don’t work well with non-ferrous metals, such as aluminum and copper. |
Used on less-than-clean surfaces | Electrodes need to be replaced frequently |
Works well in outdoor and indoor | Produce a significant amount of slag and spatter that need additional time and effort for cleanup |
Provides deep penetration, making it suitable for thicker materials and structural applications | Produces a considerable amount of smoke and fumes |
Used with a variety of metals | Slower welding speeds |
What is Stick Welding Used For?
Here are some common uses of manual metal arc welding techniques in different industries;
- Construction
- Manufacturing
- Pipeline welding
- Shipbuilding
- Automotive
- Aerospace
- Artistic welding
Frequently Asked Questions
1. What materials can be welded with Stick Welding?
Stick welding can be used on a variety of metals, including steel, stainless steel, and cast iron.
2. What are the advantages of Stick Welding?
Stick welding is versatile, portable, and effective in outdoor or windy conditions due to the flux coating.
3. What equipment is needed for Stick Welding?
Basic equipment includes a welding power supply, electrode holder, ground clamp, and consumable electrodes.
4. What are common applications of Stick Welding?
Common applications include construction, maintenance, and repair work, especially in industrial and outdoor settings.
5. What are the limitations of Stick Welding?
Limitations include a lower welding speed, a higher skill requirement, and more cleanup due to the slag produced by the flux coating.
Wrapping Up
Stick welding remains a fundamental technique in the welding industry, valued for its robustness, flexibility, and simplicity. Whether you’re repairing farm equipment in a remote location or constructing large steel structures, the principles and practices of the technique are indispensable.
With continuous advancements in electrode technology and welding equipment, the welding technique will likely remain a vital skill for welders worldwide.
