How to Use a Stick Welder

Stick welding, or Shielded Metal Arc Welding, is popular due to its simplicity, affordability, and portability.

This article will explore the basics of stick welding and provide helpful tips to guide you through the process. From understanding the equipment to learning proper methods, we will cover everything necessary to help you become knowledgeable in stick welding.

Understanding Stick Welding

Safety Procedures

Wear welding gear such as gloves, safety glasses, and fire-resistant clothing. And ensure good ventilation in your work area before stick welding.

Equipment Overview

Stick welding requires specific equipment. Some of the requirements are:

• Welding machine: A power source designed for stick welding. They can be either AC, DC, or AC/DC.
• Electrode holder and cable: A sturdy holder and cable to connect the machine with the welding rod.
• Ground clamp and cable: Connects the workpiece to the welding machine and completes the electrical circuit.
• Welding helmet: A protective shield with an auto-darkening lens to avoid damage to your eyes during the welding process.
• Chipping hammer: To remove the slag produced while welding.

Welding Materials

Welding materials are important for stick welding. 

Here are some key points:

• Base Material: The material you plan on welding, such as steel or aluminum. Preparation is important; this includes cleaning and removing dirt, rust, or paint.
• Welding Rods: Choosing the right welding rod is essential. Factors like the type of base material, required strength, and welding position must be considered. Common rods include:
  • E6010: Effective on dirty or rusty materials; suitable for pipe welding.
  • E6011: Suitable for AC machines, with similar properties as the E6010.
  • E6013: Ideal for beginners, provides a smooth weld bead.
  • E7018: Provides strong, high-quality welds and is typically used in structural applications.

Practical Application

How to Use a Stick Welder

Safety and Preparation

1. Always wear safety glasses when working with metal to protect your eyes from hazards.

2. Work on a flat, secure surface in a well-ventilated area to avoid exposure to harmful welding fumes and dust particles.

3. Use an electric grinder to clean the surfaces you intend to weld, removing grease and rust for optimal welding rod penetration

4. Before turning on the welder, ensure all arc welding safety equipment is properly positioned to protect yourself from intense light and potential burns.

5. Wear protective gear such as leather chaps, tight vests, a skullcap or beanie, a welding hood, gloves, knee pads, and sturdy boots for maximum safety.

Tacking and Welder Function

6. Securely connect the grounding lock of the welder unit to the metal you want to join to prevent electrical shock during welding.

7. Place the arc welding rod in the stinger without using your hands to avoid potential electric shock from sweating.

8. Set the welder's amperage to 100 amps, flip down your welding hood, and strike the arc on the end of the metal pieces to create a liquid metal paddle.

9. Tack the pieces together at the ends and center, temporarily holding them in position.

10. Clean off the tacks with a welding chipping hammer to ensure clean welds with significant penetration in the metal pieces.

Completing the Weld

11. Start welding from the left side of the metal pieces, as it's generally easier to weld from left to right.

12. Strike the arc by pushing the rod into the joint, creating a quarter-inch wide puddle while moving your rod in a half-circle motion to the right.

13. Continue welding until the rod is approximately one inch long, then clean the weld slag and inspect the design and penetration of the weld.

14. Ensure the weld has a continuous moon shape for a good-looking finish. Practice is key to achieving a perfect weld.

Following these steps, you can use a stick welder to join metal pieces and securely create durable welds.