Overhead Welding: How to Weld with MIG, Stick, and TIG

Welding in a flat position is a breeze, but now and then, you'll have to tackle the challenging task of welding above your head. The complex nature of trade often involves out-of-position welding, including overhead welding (4G, 4F).

Overhead welding is the most challenging welding position, as you are working against the most potent natural force: gravity. The gravity pulls down molten metal, which can end up falling on your face. Therefore, in addition to being hard to control, overhead welding also poses a risk.

We compiled this detailed overhead welding guide to explain the challenges and risks of the 4G position and provide helpful tips and tricks to keep you safe and help you make sound welds.

Overhead Stick Welding Process
Photo by @1k_cejay (TikTok)

What is Overhead Welding (4G, 4F)?

Overhead welding is a welding position where the workpiece is above the welder’s head, and the weld face faces downward. It is one of the most challenging yet valuable welding positions often used in industrial applications and environments.

To successfully perform a weld, you'll have to lean backwards, crane your head all the way back, and keep both of your hands overhead as you wiggle the torch or a gun. Assuming an awkward position like this is known as out-of-position welding.

Overhead Stick Welding in the 4G Position
Source: https://www.youtube.com/watch?v=qzkGJP4Los0&t

Out-of-position welding involves all positions other than the preferred flat position, including overhead welding, which we are discussing today. If you look at the codes, overhead welding is known as:

• 4G (Overhead groove welds): Involves overhead welding metal plates by filling a shaped gap (groove) cut into their edges. Groove welds are ideal for butt joints (square grooves) and for thicker plates, using preparations such as V, U, and J.

• 4F (Overhead fillet welds): Overhead welding metal pieces that form a triangular cross-section at an angle (often 90 degrees) in lap, T, or corner joints. Fillets are ideal for general fabrication, such as structural steelwork, where they join flanges, plates, and bracing.

Why is Overhead Welding Difficult?

The main reason overhead welding is difficult, especially for beginners and less experienced welders, is gravity. Gravity is a fundamental force that pulls any object with mass energy towards the center of the Earth, including the molten metal from your welds.

As the arc heat melts the base metal and the electrode, they become liquid. In overhead welding, the weld face is downward, so gravity pulls the liquid metal out of the joint. A lack of metal in the joint leads to incomplete fusion and penetration, resulting in weak welds.

Another issue is that molten metal and sparks can land on your face or jacket. Although you won't be directly welding under the joint, flying spatter and sparks can still burn your helmet or protective equipment.

Overhead welding sparks can burn through protective gear.
Source: https://www.youtube.com/watch?v=6W45Hz4u7dc

Common Issues With Overhead Welding

Failing to adjust the technique for overhead welding leads to several issues. Besides the common welding defects, such as porosity or spatter, here are the typical overhead welding issues:

• Molten metal dripping: Running too hot and/or too slow can create large molten blobs that tend to fall out of the joint. Gravity pulls harder on a larger puddle, so try to keep it as small as possible. 

Molten Metal Dripping in Overhead Welding
Source: https://www.youtube.com/watch?v=ZhEy8ULn1sI

• Physical fatigue: Welding out of position with both hands above the head can cause fatigue that affects your technique. Awkward positioning makes it difficult to maintain a consistent arc, speed, and puddle control, leading to various weld defects.

• Undercutting: The groove forms at the edge of a weld (the toe) because the filler metal distribution is uneven. Undercutting is typical with overhead welding because gravity pulls the metal from the top edge.

Undercutting in Stick Overhead Welding
Source: https://www.youtube.com/watch?v=AvGXWT2ipq4

• Lack of fusion and penetration: Dealing with gravity requires you to weld faster than usual when overhead. However, if you just run through the weld without providing suitable penetration, you'll get a lack of fusion or penetration.

• Burns: Spatter and molten metal dripping can burn you, even if you are not positioned directly underneath the weld. To protect yourself, use high-quality PPE.

Spatter and Sparks in Overhead Stick Welding
Source: https://www.youtube.com/watch?v=FHac7I1p7hA&t

How To Deal With Gravity in Overhead Welding?

To deal with the gravity during the overhead welding, you will need to rely on two things:

• Surface tension: This is the tendency of liquid surfaces at rest to shrink into the minimum surface area possible. Minimizing the surface area prevents them from immediately breaking apart or falling straight down. For you as a welder, that means creating a smaller bead that will resist external forces and prevent it from dripping out of the joint.

• Arc force: The arc has limited physical force. This force depends on the voltage or arc length. In a nutshell, the tight arc pushes the liquid metal into the joint, preventing it from dripping and falling out of the overhead joint.

Understanding the fundamentals of surface tension and arc force is the first step in addressing the challenges of gravity in overhead welding. However, let's get to the practical tips that will help you master your technique and improve your overhead welding.

Overhead Stick Welding in the 4F Position
Source: https://www.youtube.com/watch?v=xIm5J4xD24A

Overhead Welding Tips For Most Common Welding Methods

You'll mostly see welders weld out of position in Stick welding (Shielded Metal Arc Welding), as it is common in industrial applications and projects that involve working in awkward positions. However, you can weld overhead with any of the four most popular arc welding methods (MIG, TIG, Stick, or Flux Core welding).

Overhead Welding with MIG, TIG, Stick and Flux Core
Source: https://www.youtube.com/@Welddotcom/featured

Regardless of the method, essential tips for overhead welding are:

• Keep the arc tight

• Weld faster

• Reduce the heat to get a smaller, faster freezing bead

• Control the bead

• Protect yourself from molten metal and sparks

These are general helpful tips, but let's explore process-specific tips that provide a more detailed explanation.

Stick Welding in the Overhead Position
Photo by @datboimiggz (TikTok)

MIG Welding Overhead Tips

To MIG weld overhead, you'll need to consider the same basic principles as with flat (horizontal) MIG, but with some tweaks that address the challenges of 4G. Here are the essentials of MIG welding overhead tips that will help you get the best out of this challenging position.

4G Overhead Position MIG Welding
Source: https://www.youtube.com/watch?v=IPow-h1ia1Y

1. Use short-circuit transfer

Short-circuit transfer is a low-voltage, low-heat method in which the wire electrode contacts the base metal, creating a brief electrical short that melts and deposits a small drop of metal. A small drop of metal forms a small, easily controlled bead that freezes faster, making it perfect for fighting gravity.

Short Circuit Transfer in MIG Welding
Source: https://weldingpros.net/short-circuit-mig-transfer/

To get a short-circuit transfer, reduce the voltage and adjust the wire feed speed to keep that arc tight and crisp. You will need a proper wire feed speed to create a force to push your filler metal into the weld joint.

However, don't overdo it, as it will cause excessive spatter or burn-through on thinner pieces. You'll know you've hit a sweet spot if you hear a distinct "bacon frying" sound that the short circuit produces.

MIG Overhead Welding Process
Source: https://www.youtube.com/watch?v=JHqINcB08lE

2. Move fast

Don't hang around too much; lay your bead of weld as quickly and efficiently as possible. Spending too much time in one place will build up the bead, causing excessive metal to drip down.

However, don't just run through the joint, as you can get insufficient penetration and fusion. To balance the travel speed, consider increasing the wire feed speed (amperage).

Getting the correct parameters for overhead MIG can take some time. The key is to find a sweet spot where you move fast enough so you don't pile up the metal, but with enough heat to properly fuse and penetrate the pieces.

MIG Welding in the Overhead Position
Photo by @glamourovermatter (TikTok)

3. Shorten the stick out and arc length

To get better control over the smaller weld bead, shorten the stickout and tighten the arc. A stickout that is too long will be harder to control, and it can make a bigger mess, which is not what you want with overhead welding.

Using a shorter stickout will help you run closer to the joint and keep a tight arc. A tight arc provides much better control and cleaner welds, while preventing you from running the arc all over the joint.

4. MIG torch movement matters

When learning to weld overhead, hold the MIG torch with both hands. It gives you greater control over the welding torch as you learn, and helps you avoid wandering arc across the joint.

Hold MIG Torch with Both Hands While Overhead Welding
Photo by @laylakaty (TikTok)

Avoid using a sharp travel angle. Sharp travel angle creates a wandering arc, making it hard to see what you're doing. A slight torch angle lets you see and control the puddle much better.

Most welders recommend running a tight circular pattern to compensate for the smaller bead. Dragging the torch in a tight circular motion will balance the deposition with the increased wire feed speed required for overhead MIG.

However, keep in mind that torch movement can vary depending on the given project and metal thickness. On thin metals, stringers will avoid heat buildup. Nevertheless, on wide gaps, you'll need more weaving to fill the toes and provide a proper tie-in.

Consider using multiple passes on wider gaps. Using small beads to avoid weld dripping means you'll need to run a few passes to fill the wider gap. That way, you'll strengthen the weld while addressing issues with overhead welding.

MIG Overhead Welding Process
Photo by @raulmendez036 (TikTok)

5. Increase the gas flow

Since shielding gases are lighter than air and will rise, there may be signs of gas loss in overhead welding. Increasing the flow can compensate for the loss, but do this only if you notice porosity caused by improper shielding.

Be careful if the welding process produces excessive fumes. In flat welding, the fumes rise, but in overhead welding, they can move down into the nozzle. Mixing fumes with shielding gas can create turbulence that sucks in the contaminants into the weld. Increasing the flow can form a protective barrier, but it can also cause turbulence, so be careful.

Laminar vs. Turbulent Flow in MIG Welding
Source: https://vaneselectric.com/blogs/news/mig-welding-gas-flow-rate-explained-with-charts

Stick Welding Overhead Tips

Shielded metal arc welding is one of the methods you'll see overhead welding used the most. Industrial applications, repairs, pipeline welding, and many other situations involve stick welders joining pieces in uncomfortable positions, above their heads.

Industrial Stick Welding in Overhead Position
Source: https://www.youtube.com/watch?v=D3rJEgBMoZU

1. Lower the amperage

Stick welding runs very hot, and melting too much metal creates a fluid puddle that will sag and fall out of the joint. When stick welding overhead, you'll want to lower the 5-15 amps you would use in the flat position.

The key is to get the puddle to freeze fast enough so it doesn't drip out of the joint, while retaining proper penetration and fusion. But be careful not to overdo it.

If you lower the amperage too much, the electrode will stick to the base metal. Finding a sweet spot can take some time for beginners, and you'll also have to adapt the parameters to your technique, equipment, and conditions.

 Electrode Sticking to the Base Metal
Photo by @madomm_world_ (TikTok)

2. Keep your arc length short

The tighter the arc gets, the better control you'll get over the weld puddle. If you shove the electrode into the joint, you'll get a tight arc that allows you to control the puddle perfectly.

The science behind a tight arc is simple. The closer you move the electrode to the joint, the lower the voltage. Lower voltage produces a narrower bead that is easier to control and less likely to drip from the joint.

In addition, the closer you get to the joint, the more arc shoves the metal inside the joint. The arc force acts like a jet, pushing the puddle inside the joint and preventing it from dripping.

Keep arc length short when overhead welding.
Source: https://www.youtube.com/watch?v=l0LZVxOwR8o

3. Electrode angle and manipulation for overhead welding

Stick welding overhead requires a 90-degree work angle. But, since SMAW produces excessive spatter, staying directly underneath the arc may burn your hands and face. That's why you should tilt the electrode 5-15 degrees toward your weld (drag angle).

When it comes to torch manipulation, it will depend on the joint configuration. With butt joints, you'll need a slight weaving to fill the sides and ensure good tie-in. When weaving, do not overdo it or spend too much time in the middle. Slow-moving or middle focus will build up the molten metal, which will drip.

On fillet welds (lap or t-joints), you don't need to weave. However, tight arc and puddle control are mandatory.

4. Use fast-freezing electrodes

Most welders recommend E6010 and E7018 electrodes for overhead welding. E6010s are fast-freezing electrodes that deliver a quick-starting, steady, and deep-penetrating arc. They are ideal for root pass on thicker pieces and are often used in overhead stick welding.

E7018s are low-hydrogen iron powder electrodes that improve the deposition rate and fill the joint faster. They are ideal for high-strength structural joints, and their ability to fill the joint quickly is particularly effective against gravity.

Overhead Stick Welding Using E7018
Photo by @datboimiggz (TikTok)

5. Keep yourself protected

As previously mentioned, Stick welding often runs hotter and produces more spatter and sparks than other methods. In the overhead welding position, these can easily land on your face, hands, or neck, so you will need full-body protection.

Do not weld directly under the joint, and fully cover any exposed skin with flame-resistant clothing. Consider wearing a bandana to prevent sparks from getting inside your jacket or shirt.

Overhead Welding with Bandana Protection
Source: https://www.youtube.com/watch?v=moe45EAtZsE

Overhead TIG Welding Tips

Overhead TIG is not as common as MIG or Stick, but you may occasionally need to repair an aluminum boat or a thin metal pipe in an overhead position. Here are some valuable tips that can help you.

Overhead TIG Welding of a Socket Weld
Source: https://www.youtube.com/watch?v=L6K43wQmhYA

1. Get yourself comfortable

TIG welding can be demanding to pull off, especially if you are a new welder. You are using both hands to move the torch and feed the wire, and working in an overhead position makes the challenge even more difficult.

The very first tip for overhead TIG is to try to get as comfortable as possible. Whenever possible, rest your hand or torch on the plate and use a TIG finger to avoid burning your hand.

For the best control, you will need to see the puddle clearly and smoothly feed the rod. Armrests, platforms to lie on, and anything that supports your hands while you weld are helpful and help stop your hands from shaking.

Overhead TIG welding in a Comfortable Position
Source: https://www.youtube.com/watch?v=7Y3wToJHcT8&t

2. Overhead TIG is similar to flat, just upside down

Unlike MIG or Stick welding, or even vertical TIG, overhead TIG is quite identical to flat TIG. That means you won't need to tweak the parameters much or use any special techniques.

In general, take the same approach as you would with the same thickness and configuration in a flat. Control the puddle and check the heat. TIG is less likely to spit in overhead, but if the metal builds up, it will eventually drip out of the joint.

Overhead TIG is all about consistency and cleanliness. As long as your joints are well-prepared, and you can produce even, consistent welds, you will do well in overhead.

Joint Preparation Before Overhead TIG Welding
Source: https://www.youtube.com/watch?v=YLDrviv3i9Q

3. Freehand or walking the cup?

It all depends on the joint configuration and your personal preferences. When welding thicker pieces with a root opening or fillet welds, you can always walk the cup. Weaving will help you fill a wider gap, and you can feel comfortable resting the cup on the joint.

However, if walking the cup feels overwhelming, you can always freehand overhead TIG, especially on thinner pieces. Once again, overhead TIG can be demanding, so if it is easier for you to control the puddle with freehand, nothing should stop you. As long as you feel comfortable and get reasonable control of the puddle and heat, it does not matter whether you walk the cup or freehand.

TIG Welding in Overhead Position
Source: https://www.youtube.com/watch?v=3545s_lQDIg

Final Thoughts

Overhead welding can seem daunting to any new welder, and it is indeed the most challenging and demanding welding position. You are fighting gravity as it pulls molten metal down, and you are welding in an awkward position that can cause significant physical strain.

Understanding the challenges is crucial in overcoming them. Fundamentals of fighting gravity include controlling the puddle and heat, using a tight arc to limit the size of the molten puddle, and keeping yourself safe.

Overhead MIG Welding for Repairs
Photo by @thecoloredhairedwelder (TikTok)