SMAW · Shielded Metal Arc Welding
Stick Welding
Stick welding burns a flux-coated electrode that supplies both filler metal and shielding — the most portable, most wind-tolerant and most forgiving process on dirty or rusty steel.
- SMAW
- DCEP, DCEN or AC depending on the electrode classification
- 20–350 A depending on rod diameter
- Self-shielding from the flux coating; no external gas
How stick welding works
A flux-coated electrode is clamped in a holder and struck against the work to start an arc. The metal core melts and transfers across the arc as filler while the flux coating burns, producing a shielding gas and a molten slag that covers and protects the cooling weld. The slag is chipped off afterwards. Because everything needed is in the electrode, no gas bottle is required and wind does not matter.
At a glance
| AWS designation | SMAW — Shielded Metal Arc Welding |
|---|---|
| Also called | Stick, SMAW, Arc welding, Manual metal arc, MMA |
| Polarity | DCEP, DCEN or AC depending on the electrode classification |
| Typical amperage | 20–350 A depending on rod diameter |
| Typical voltage | 20–35 V |
| Positions | All positions with most electrodes; E7024 and other 2-series rods are flat and horizontal only |
| Deposition rate | Moderate, reduced by stub loss and by stopping to change rods |
| Shielding | Self-shielding from the flux coating; no external gas |
| Skill level | Demanding at first — arc length is controlled entirely by hand |
Polarity options
| Mode | Description | Typical use |
|---|---|---|
| DCEP (reverse polarity) | Electrode positive. Deeper penetration and the standard setting for E6010, E7018 and most stainless electrodes. | Most electrodes, most work |
| DCEN (straight polarity) | Electrode negative. Shallower penetration and a higher deposition rate; used on sheet metal with E6013 and on some iron-powder rods. | Thin material, some rutile rods |
| AC | Alternating current. Required by E6011, permitted by E6013, E7014, E7018 and E7024. Reduces arc blow at high amperage on heavy plate. | Transformer machines, arc blow situations |
Starting settings
Starting points only — every machine, joint and position shifts them. Adjust by arc sound and bead profile.
| Thickness | Rod | Amps | Electrode |
|---|---|---|---|
| 1/16 in (1.6 mm) | 1/16 in | 20–40 | E6013 |
| 1/8 in (3.2 mm) | 3/32 in | 60–90 | E6013, E6011, E7018 |
| 3/16 in (4.8 mm) | 1/8 in | 90–130 | E6011, E7018, E7014 |
| 1/4 in (6.4 mm) | 1/8 in | 110–150 | E7018, E6010, E7014 |
| 3/8 in (9.5 mm) | 5/32 in | 150–220 | E7018, E7024 |
| 1/2 in and up | 5/32–3/16 in | 200–300 | E7018, E7024 |
Advantages
- Works outdoors in wind and rain where gas-shielded processes fail
- Most portable equipment — a machine, leads and a box of rods
- Tolerates rust, mill scale, paint and poor fit-up better than MIG or TIG
- Electrode range covers carbon steel, stainless, cast iron, nickel and hardfacing
- Lowest equipment cost to get welding
Limitations
- Slag must be chipped between every pass
- Deposition rate is limited by stopping to change electrodes
- Arc length is controlled entirely by hand, which takes practice
- Not practical below about 18 gauge sheet
- Low-hydrogen electrodes require rod oven discipline
Where it is used
- Structural steel erection and field welding
- Pipeline and pressure piping
- Farm, ranch and heavy equipment repair
- Shipyard and offshore work
- Maintenance welding on dirty or weathered steel
Filler metals for stick welding
E6010
AWS A5.1/A5.1M · Carbon & Mild Steel
E6010 is a DC-only cellulosic stick electrode with the deepest penetration of any common rod, used for open-root pipe…
E6011
AWS A5.1/A5.1M · Carbon & Mild Steel
E6011 is the AC-capable version of E6010 — deep penetration and a fast-freeze puddle that works on small transformer…
E6013
AWS A5.1/A5.1M · Carbon & Mild Steel
E6013 is the easy-starting rutile rod for thin steel and light fabrication — soft arc, shallow penetration and the…
E7014
AWS A5.1/A5.1M · Carbon & Mild Steel
E7014 is an iron-powder rutile rod that runs like E6013 but deposits faster and stronger — a fast-fill, all-position…
E7018
AWS A5.1/A5.1M · Carbon & Mild Steel
E7018 is the low-hydrogen structural rod — 70 ksi tensile, tough at -20 °F, all positions, and the default electrode…
E7024
AWS A5.1/A5.1M · Carbon & Mild Steel
E7024 is a heavy iron-powder drag rod for flat and horizontal fillets only — the fastest-depositing common stick…
E308L
AWS A5.4/A5.4M · Stainless Steel
E308L is the standard stick electrode for welding 304 and 304L stainless, with a low 0.04% maximum carbon that…
E309L
AWS A5.4/A5.4M · Stainless Steel
E309L is the dissimilar-metal electrode — its extra chromium and nickel survive dilution when joining stainless to…
E316L
AWS A5.4/A5.4M · Stainless Steel
E316L adds 2–3% molybdenum for pitting and chloride resistance, making it the electrode for 316/316L marine, chemical…
E347
AWS A5.4/A5.4M · Stainless Steel
E347 is niobium-stabilized stainless — the niobium ties up carbon so the weld resists intergranular attack even after…
E410
AWS A5.4/A5.4M · Stainless Steel
E410 is a 12% chromium martensitic stainless electrode for matching 410 base metal and hardfacing — it air-hardens…
Stick Welding — common questions
What does SMAW stand for?
Shielded Metal Arc Welding. It is the formal AWS name for what most people call stick welding, arc welding, or manual metal arc (MMA) welding.
What amperage should I set for stick welding?
A rough starting rule is one amp per thousandth of an inch of electrode diameter — about 125 A for a 1/8 in rod. Then adjust by sound and bead profile, and drop 10–15% for vertical and overhead.
What is the difference between DCEP and DCEN?
DCEP puts the electrode positive, which places about two-thirds of the heat in the work and gives deeper penetration. DCEN puts the electrode negative for shallower penetration and higher deposition. Each electrode classification specifies which it needs.
Which stick electrode should a beginner start with?
E6013 on 1/8 in plate. It strikes easily, runs on almost any machine and is forgiving of arc length. E7018 is the rod to learn next, because most structural work requires it.
Why does my stick electrode keep sticking?
Usually the amperage is too low, or the arc was struck straight down instead of scratched like a match. E7018 in particular needs a scratch start slightly ahead of the joint, then a drag back into the puddle.