Smaw

Shielded Metal Arc Welding
(SMAW)
 Shielded metal arc welding is an electric arc welding process that joins metals
together using a consumable electrode. It was first introduced in 1888 when
Nikolay Gavrilovich Slavyanov used consumable electrodes as a tool to arc
weld.
 Shielded metal arc welding, commonly known as stick welding, remains to be

one of the most commonly used welding techniques today. Stick welding is an
immensely versatile welding process, as we can use it in almost any industry,
environment, position and metal.
 Let’s further dive into what differentiates stick welding from other welding
processes.
What is Stick Welding
STICK WELDING SYSTEM STRUCTURE
(1) Main connection
(2) Power source
(3) Welding power-lead (electrode)
(4) Grounding cable (workpiece)
(5) Electrode holder
(6) Earthing clamp
(7) Rod electrode
(8) Workpiece
What is Stick Welding
Stick welding also known as manual arc welding, manual

electrode welding, manual metal arc welding or shielded
metal arc welding (SMAW) is usually the first welding process
that welders are taught during training. It is easy to learn, but
already offers insights into the way that welding systems work
and into the ratio of metals to electrical voltage.
Shielded Metal Arc Welding Process
Before welding, ensure your equipment is in good condition,

including a well-functioning power source, clamps, cables, and
electrode holder. Select an electrode that complements the base
metal and set the power supply in the correct setting. Start the arc
welding process by striking the base metal with the electrode,
maintaining a constant arc length, and remove slag after cooling the
weld metal.
Electrodes
Electrode 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″ (35cm) or 18″ (45cm) and the welder
has to manually change them.
Stick welding electrodes are classified into three main
categories:
• Cellulosic electrodes
• Rutile electrodes
• Basic electrodes
Cellulosic electrodes
Cellulosic electrodes 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).
Rutile electrodes
Rutile electrodes 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.
Basic electrodes
Basic electrodes 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.
Power Source
 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.
 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.
Materials
Stick welding is usually the best choice when welding thicker metals, while other methods such as TIG
and MIG welding are preferred for thin materials.
These are the materials that you can stick weld:

• Steel
• Stainless steel
• Chrome
• Nickel-based alloys
• Iron
• Mild steel
• Aluminum
Reactive materials such as zirconium, tantalum, columbium, and titanium aren’t recommended for this
welding technique. The primary reason for this is that the shielding properties are insufficient for
protection against contamination.
Welding Machine
 A ground clamp - is needed to prevent electrical shock. It needs to be connected to the work
piece or fixture. The ground clamp must be capable of carrying the electric current without
overheating to avoid hazards.
 Welding cables - used in SMAW are flexible and insulated. They must have a sufficient cross-
sectional area and length to carry out the welding current with minimal voltage drop. There are
two welding cables in a stick welding machine, one for the electrode holder, and the other for the
ground clamp.
 An electrode holder - delivers the welding current to the electrode. It acts as a guide to
precisely feed the electrode to the weld joint. Electrode holders vary in size and possess different
current capacities.
Shielded Metal Arc Welding Variables
1. Arc length
2. Amperage
3. Travel speed
4. Welding Techniques
5. Welding Positions
1. Arc length - is one of the most crucial factors in stick welding. Different electrode
materials and welding applications will determine the optimal arc length for the project.
As a rule of thumb, the arc length should never surpass the diameter of the core wire.
2. Amperage - is influenced by the electrode angle and type. For example, a fast filling
electrode may allow you to have a higher travel speed. Changing the travel speed
incorrectly may leave a frail and shallow weld, since the deposits formed may be more or
less than required.
3. Travel speed - is influenced by the electrode angle and type. For example, a fast filling
electrode may allow you to have a higher travel speed. Changing the travel speed
incorrectly may leave a frail and shallow weld, since the deposits formed may be more or
less than required.
4. Welding Techniques – Compared to other welding methods, the SMAW welder has more
influence than the machine in determining the weld quality. Here are some of the patterns and
techniques that are suited for different projects:
• Whipping the electrode - works best on low-flux electrodes such as E6010, E6011 and E6013
that can be trapped in the weld. Whipping helps to burn and remove contaminates from the
forward and back motion.
• The circle technique - is mostly used by beginners since it can create a consistent travel
speed and works with most electrodes. Simply move forward slightly with each circular motion.
• Weaving - is generally used when wider welds are required. It is performed by moving the
electrode side to side after striking the arc.
5. Welding Positions - Stick welding is one of the most versatile welding techniques and it can be
performed at varying angles, including flat, horizontal, vertical and overhead welding positions.
Advantages of Stick Welding
1. Stick welding can be performed in almost any environment.

2. Equipment is rather cheap and affordable.
3. Easy to use in tight spaces.
4. Many available electrodes to choose from.
5. Metal surfaces don’t have to be cleaned as rigorously as for example
in TIG welding
6. Can be used for a variety of metals and alloys, along with unique
positions.
7. Portable and lightweight equipment, no need to carry a gas tank
around.
8. Gases produced are sufficient for protecting the weld metal.
Applications of Stick Welding
• Maintenance and Repair - Stick welding is versatile and highly mobile,

which makes it perfect for quick repairs, even in harsh conditions. A stick
welder can be used in windy conditions, rain and underwater, without
compromising its weld quality. Stick welding’s unique trait is that it can
weld unclean or rusty metals.
• Fabrication - Since shielded arc welding is fairly easy to learn and
welding equipment is cheap, it is still one of the most popular methods in
fabrication and construction. While some industries are shifting to more
automated welding methods, many still prefer to use stick welding.

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Shielded Metal Arc Welding

 Shielded metal arc welding, commonly known as stick welding, remains to be

Stick welding also known as manual arc welding, manual

Before welding, ensure your equipment is in good condition,

These are the materials that you can stick weld:

1. Stick welding can be performed in almost any environment.

• Maintenance and Repair - Stick welding is versatile and highly mobile,

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