Let’s further dive into what differentiates stick welding from other welding processes.<\/p>\n
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- Shielded metal arc welding, also known as stick welding<\/strong>, is widely used across various industries due to its ability to weld a broad range of metals<\/strong> and operate in different welding positions and environments, including challenging conditions.<\/li>\n
- The stick welding process involves a consumable flux-coated electrode<\/strong> that melts to form a weld pool, while the flux generates a protective gas to shield the weld<\/strong> from contamination.<\/li>\n
- SMAW is portable, cost-effective, and doesn\u2019t require rigorous surface cleaning<\/strong>, but it can produce slag and requires skill to avoid defects.<\/li>\n
- Choosing the right electrode<\/strong> type\u2014cellulosic, rutile, or basic\u2014is crucial as it influences arc stability, weld quality<\/strong>, and ease of slag removal.<\/li>\n <\/ul>\n <\/div>\n \n
What Is Stick Welding<\/h2>\n
![\"shielded](\"https:\/\/fractory.com\/wp-content\/uploads\/2022\/08\/stick-welding.jpg\")
<\/p>\nShielded metal arc welding (SMAW), also known as manual metal arc welding (MMAW or MMA) is a welding process that uses a flux-coated electrode to join metals.<\/p>\n
An arc forms when the electrode tip comes into contact with the workpiece. Fusion takes place as both the rod and workpiece melt, forming a weld pool from the molten metal.<\/p>\n
Simultaneously, the flux coating of the electrode<\/strong> is consumed, forming a protective layer of shielding gas and slag<\/strong> in the weld area.<\/p>\n
Slag deposits will eventually form in the weld bead as the metals cool down. The deposits in the weld metal can be chipped off using common shop tools.<\/p>\n
This manual metal arc welding technique is limited to short weld stints, as the consumable electrode needs to be constantly replaced.<\/p>\n
SMAW should not be confused with FCAW although they share some similarities. With both welding processes, the flux from the electrodes protects the molten weld metal from contamination. These processes do not necessarily need external shielding gases but there are differences in the electrode design and thus, flux-cored arc welding<\/a> is sometimes referred to as stick welding turned inside out<\/p>\n
Shielded Metal Arc Welding Process<\/h2>\n
Before welding, it is always recommended to check the condition of your equipment. It is crucial for both safety and welding quality to have a well-functioning power source, clamps, cables and electrode holder.<\/p>\n
The next step is to select an electrode that will complement the base metal. Simultaneously, the power supply must be set in the proper setting: direct current electrode negative, direct current electrode positive, or alternating current. One wire in a stick welder is attached to the ground clamp and the other is linked to the electrode holder.<\/p>\n
To start the arc welding process, the base metal is struck with the electrode. A welding arc forms as the electrode melts in the weld pool.<\/p>\n
Consuming the flux coating releases a shielding gas that protects the weld pool from atmospheric contamination. A constant arc length should be maintained as the covered electrodes slowly join the molten pool. Generally, the arc length should be approximately equal to the diameter of the core wire.<\/p>\n
A layer of slag forms as the weld metal cools. It can be removed post-cleanup using a chipping hammer and a steel brush.<\/p>\n
Electrodes<\/h3>\n
![\"a](\"https:\/\/fractory.com\/wp-content\/uploads\/2022\/08\/stick-welding-electrodes-e1659618029577.jpg\")
<\/p>\nElectrode type is one of the determining factors in ensuring weld quality. Its chemical composition can influence the arc stability, deposition rate, depth of penetration and other factors. The electrodes come at a fixed length of 14\u2033 (35cm) or 18\u2033 (45cm) and the welder has to manually change them.<\/p>\n
Stick welding electrodes are classified into three main categories:<\/p>\n
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Cellulosic electrodes<\/strong> have a high cellulosic proportion in their coating which is suitable for deep arc penetration and high weld speeds from its rapid burn rate. They can be used for any welding position, but the high levels of hydrogen have to be taken into account as it increases the risk of cold cracking in the heat-affected zone (HAZ)<\/a>.<\/p>\n<\/li>\n
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Rutile electrodes<\/strong> contain high amounts of titanium oxide (rutile) in the flux. This material helps promote lower spatter, a good bead profile and consistent arc operation. These electrodes can be used in almost any welding position and are usable in both AC and DC power sources. They also create a fluid and viscous slag that is easy to remove.<\/p>\n<\/li>\n
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Basic electrodes<\/strong> have high quantities of calcium chloride and calcium carbonate in their coating. They are used for welds that require good mechanical properties and resistance to cracking. Basic electrodes are suitable for high weld speeds since the slag freezes fast. This also comes in handy when welding in the vertical and overhead positions but in turn, the slag is harder to remove, and thus these electrodes are prone to create poor bead profiles.<\/p>\n<\/li>\n<\/ul>\n
On another note, metal powder electrodes have a flux coating with iron powder to promote a higher welding current. Compared to electrodes with no iron powder, metal powder electrodes have higher deposition rates and efficiency.<\/p>\n
Power Source<\/h3>\n
Stick welding can be used in both alternating current (AC) and direct current (DC) power sources. The power source, whether DC negative, DC positive, or AC, should be set depending on the type of electrode.<\/p>\n
The welding machine requires a constant current, which is determined by the electrode size. The voltage will depend on the arc length and rod composition and can be regulated by moving the electrode closer or farther from the workpiece.<\/p>\n
\n\n Scale Your Manufacturing from Prototyping to Series<\/span>\n\n- \n
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- The stick welding process involves a consumable flux-coated electrode<\/strong> that melts to form a weld pool, while the flux generates a protective gas to shield the weld<\/strong> from contamination.<\/li>\n