Stick Welding Tips For Beginners

Stick welding is one of the oldest but, indeed, the industry's most popular welding methods. It allows welders to tackle any job quickly and cheaply.

However, skill-wise, Stick welding is one of the more demanding methods. The Stick is a manual welding technique, meaning you manually control most parameters, making it more challenging than MIG or Flux core, but not as hard as TIG welding.

If you just started welding and decided to go with the Stick, you can have a hard time. That's why we compiled these Stick welding tips for beginners to help you understand and master this versatile welding technique.

Stick Welding Process
Source: https://www.youtube.com/watch?v=hytW79WlPb0&t=38s

Stick Welding Basics

Stick welding is an arc welding method, which means it uses the heat of an arc to melt and fuse the pieces. The arc forms between the consumable electrode and the base metal.

Stick Welding Basic
Source: https://www.longevity inc.com/resources/resources/improving-your-skills/stick-welding-basics

Shielded Metal Arc Welding (SMAW) uses self-shielded electrodes. The core of the electrode is covered with flux. Once the flux melts, it creates a layer of slag that protects the puddle from atmospheric contamination.

Unlike gas welding processes, such as TIG or MIG welding or TIG, you don't need an external shielding gas with Stick. That means you can weld outdoors without the risk of wind or draft blowing away the shielding gas.

Low equipment cost and the ability to work outdoors make Stick one of the industry's favorites. Stick welders such as YesWelder Arc 205DS are not costly and won’t break your bank. However, like TIG welding, Stick is a manual welding technique, meaning it can be somewhat more challenging to master than semi-automated methods.

ARC-205DS-PRO 110V/220V Stick& Lift TIG In One Stick Welder

Stick Welding Tips And Techniques for New and Beginner Welders

As noted, Stick welding can be challenging to master, especially for new welders just getting into the trade. The first experience with starting and maintaining the arc can be a nightmare, but don't let that discourage you.

With a bit of practice and our valuable tips, you can avoid spatter, electrode sticking to the base piece, or extinguishing the arc. So, let's see what you can do to improve your Stick welding.

Tips to Improve Stick Welding
Photo by @weldsnmore (TikTok)

1. Safety First!

Welding is a hazardous profession, so always prioritize safety. Stick welding produces high heat, spatter, radiation, and toxic fumes, so ensure you are well-protected before starting to weld.

Always wear flame-resistant gloves, jacket, and pants to protect your skin from burns and molten sparks. Use a welding helmet with a high shade level to protect your face and eyes from IR/UV radiation. Radiation can cause severe sunburns and a corneal injury known as arc eye, which is similar to a sunburn on the surface of the eye.

YesWelder Auto-Darkening Welding Helmet

Burning the flux can create toxic fumes. Prolonged exposure can cause metallic fume fever or damage your lungs, so try to work in a well-ventilated area. When welding in cramped spaces, use a welding respirator or local ventilation.

Toxic Fumes Created in Stick Welding
Photo by @weldsnmore (TikTok)

2. Preparation Is Crucial

The more time you spend preparing for welding, the less time you'll worry about post-weld cleaning or rework. Welding preparation includes cleaning, aligning, and fitting the pieces to provide clean surfaces and even gaps through the joint.

Although Stick welding can burn through light contamination or thin layers of dirt, rust, oil, or paint, it is always better to clean the surfaces before welding. E6010 or E6011 electrodes can burn through contamination, but burning paint, oil, or rust can create messy welds with excessive spatter and toxic fumes. So, cleaning the pieces with a wire brush or an old rag can yield much cleaner and safer results.

Clean the Metal Surfaces Before Welding
Source: https://www.youtube.com/watch?v=FF_9qGJnXRU

Use a grinder or chemical solutions for thicker contamination. Mill scale, thick rust, or dirt can significantly affect welding performance, especially in thick layers.

By properly aligning and fitting the pieces, you create an even gap across the joint. You can tackle the pieces before welding to keep everything in place. As a beginner or new welder, stick to horizontal and flat positions and butt welds or T-joints. The gravity pulls the weld puddle inside the joint, so you'll get a proper tie-in and fusion.

Properly Align and Fit the Pieces Before Welding
Photo by @ironcraftingtips25 (TikTok)

3. Use the Right Size Electrodes

Stick electrodes come in various sizes and compositions, so choosing the right one for your applications can be challenging. Unfortunately, there is no one-size-fits-all electrode, but there are some types and sizes you are likely to use as a beginner or new welder.

Electrode Size & Amperage Chart

As a rule of thumb, you should always select a rod that is one size smaller than the base metal. For example, if the base metal thickness is 1/8″, use a 3/32″ rod. This rule works well on thicknesses up to 3/16".

As a beginner, you'll probably use 3/32", 1/8", and 5/32" electrodes. These will cover most medium-thickness steel in your garage or workshop.

Using an electrode that is too large requires more amps to run. The more amps you use, the higher the chances of burning through the base metal. Using an electrode that is too small can create a lack of fusion or penetration, underfill, or poor tie-in.

Stick Welding with the Right Size Electrodes
Photo by @arclabsweldingschool (TikTok)

Learn more about Stick welding rod sizes in this comprehensive article.

4. Choose the Suitable Electrode Type

Stick electrode specifications show dozens of electrode types, and many wonder which one to choose. The most widely used electrodes are E6010, E6011, E6013, E7018, and E7024, each showing different results in various applications.

Most Commonly Used Welding Electrodes 
Source: https://www.materialwelding.com/

We recommend using E7018 for absolute beginners and new welders. 7018 is an all-position electrode with a high iron powder content, which makes it highly forgiving and easy to use. It produces a smooth, quiet arc with minimal spatter and medium penetration. Additionally, E7018 works great with clean surfaces and produces clean, aesthetic welds.

E6011 electrodes work great on thinner and cleaner materials, while E7024 provides excellent penetration on 1/4" plates and thicker materials. E6010 is a notorious electrode with a highly tight arc and high dig. It can burn through contaminants, and welders often use it for a root pass. However, it is one of the hardest to use and control, so we don't recommend it to new welders.

E6010 Stick Welding Process
Photo by @hunter.hanson22 (TikTok)

5. Use the Scratch Arc Start Technique

There are several ways you can start an arc with stick electrodes, with the most popular being the scratch technique and tapping technique. In the scratch technique, you scratch the surface of the metal with the tip of the electrode until the arc forms. Meanwhile, the tapping technique involves tapping the surface with the tip of the electrode.

Among the two, scratching is known as being more beginner-friendly. The entire motion reminds us of lighting the match and is highly intuitive. Once the arc forms, you maintain the consistent length and weld across the joint.

Some seasoned welders prefer the tapping technique. While tapping the surface with the tip is relatively easy, if you spend a second more than you should, your electrode can stick to the base piece. That's why we recommend scratch arc start to beginners, but you can start according to your personal preferences.

Scratch vs. Tapping Start Techniques
Source: https://www.wcwelding.com/arc-welding-tips.html

6. CLAMS

The stick welding technique highly depends on five essential elements you can remember by the acronym CLAMS:

• Current

• Length of the arc

• Angle of the electrode

• Manipulation of the electrode

• Speed of travel

Bringing together all these elements will result in high-quality, satisfying Stick welds, but mastering them can take time and patience. Let's briefly explain how each aspect of the technique can affect your final Stick welding results.

Stick Welding with E6010 Electrodes
Photo by @mainlineleo (TikTok)

Current in Stick Welding

Stick welding is one of the few welding methods that can operate at DC- (DCEN), DC+ (DCEP), or AC current. The correct current and welding polarity will mostly depend on the electrode, welding project, and manufacturer recommendations, but there are some rules.

Source: https://www.perfectpowerwelders.com/what-is-polarity-in-welding-and-different-types-of-welding-polarity/

In Stick welding, DCEP (Direct Current Electrode Positive) polarity provides approximately 10% more penetration at the same amperage than DCEN. Direct Current Electrode Negative (DCEN) polarity is more suitable for thinner metals as it produces less penetration. AC Stick welding can be inconsistent but helpful in specific applications. We recommend AC when trying to deal with arc blow defect, in which the arc wanders from the shortest path.

Choosing the amperage will depend on the thickness of the metal and the manufacturer's recommendations. A general rule of thumb is 1 amp for each .001-inch of electrode diameter. Using an amperage that is too high can cause excessive spatter and burn-through. Using an amperage that is too low will extinguish the arc or stick the electrode to the base metal (ergo, the name Stick welding).

Electrode Sticking to Base Metal
Photo by @bernardosanchez388 (TikTok)

Length of the Arc in Stick Welding

Arc length is defined as the distance from the tip of the electrode to the weld puddle. As a rule of thumb in Stick welding, the arc length should not exceed the core diameter of the electrode. For example, you should hold a 1/8-inch electrode about 1/8 inch away from the base material.

Arc Length in Stick Welding
Source: https://www.cruxweld.com/blog/five-steps-to-improving-your-stick-welding-technique/

The arc length affects the overall voltage of the weld. Holding the electrode too close to the weld puddle decreases the voltage. Low voltage produces an erratic arc, which can cause fast electrode freezing and electrode sticking to the workplace.

Holding the electrode too far from the weld puddle increases the voltage. High voltage lowers the deposition rates and creates excessive spatter, undercuts, and sometimes porosity. As a beginner, you are likely to use a longer arc length to see the puddle correctly. So, try to find a comfortable position in which you can see the puddle and use the tighter arc.

The Effect of Arc Length in Stick Welding
Source: https://www.mig-welding.co.uk/arc-welding-faults.htm

Angle of Travel

The travel angle in Stick welding is the angle at which you tilt the electrode as you weld across the joint. To stick weld properly, hold the electrode perpendicular to the joint.

In horizontal and flat welds, you hold the electrode at 90 degrees, and in Tee joints, it is at 45 degrees (working angle). Then, tilt the top in the direction of travel approximately 5 to 15 degrees. When working in overhead or vertical positions, lower the travel angle to 0-15 degrees.

Work Angle vs. Travel Angle
Source: https://constructionmanuals.tpub.com/14250/css/Arc-Welding-Positions-144.htm

Manipulation of Electrode

Each welder has its unique way of manipulating or moving the electrode across the joint. However, there are two primary types of welding beads: stringer and weaving.

 Weave Bead vs. Stringer Bead

As a beginner welding metals thinner than 1/4", you should use stringer or straight beads. You can fill the smaller gap by moving in a straight line with little or no side-to-side movement. In addition, this is a much easier way to manipulate the electrode than weaving.

Weaving in Stick welding involves zig-zagging across the joint, creating a much wider weaving bead. The torch movement shows a series of patterns, such as crescents, circles, letters Z, ladders, and many more. You must use weaving when filling larger gaps on metals thicker than 1/4". However, mastering the technique of filling large joints requires a lot of time and practice.

Stick Welding Zig-Zag Pattern
Source: https://www.youtube.com/shorts/Te5Gm0jCJVQ

Speed of Travel

Travel speed denotes how fast you move the torch across the joint. As a general rule, you should go fast enough to keep the arc in the leading one-third of the weld pool.

Keep Travel Speed Consistent
Source: https://www.youtube.com/shorts/OF1R2zy_FbU

Moving too fast across the joint will negatively affect the penetration and fusion. Just running through the joint won't provide adequate heat exposure. It will produce narrower and highly crowned beads with improper tie-in, lack of fusion, or penetration.

The only time you should move fast is when welding vertically up or overhead. Even though beginners are less likely to work in these positions, it is worth knowing that moving fast will control the weld puddle and prevent it from slipping away from the joint.

Moving too slowly across the joint causes excessive heat exposure to the joint.  Instead of penetrating, the molten metal creates a wide convex bead that sits on top of the weld. On thinner metal, slow travel speed will also cause a burn-though.

How Different Factors Affect the Weld
Source: https://www.linkedin.com/pulse/arc-welding-faults-aboul-kalam-azad

7. Always Drag with Stick Welding

Remember: When there is slag, you drag!

When using slag welding methods such as Stick welding and Flux-cored arc welding, you should always drag (pull or backhand). Using the backhand technique allows you to see and control the puddle, but it also avoids slag inclusions.

Use the Drag Technique in Stick Welding
Source: https://www.youtube.com/watch?v=truGsGGLKV8

The only exception is Stick welding in a vertical-up position. Pushing the puddle from the bottom to the top of the weld will help you control the puddle and prevent it from slipping away from the joint.

8. Properly Store the Electrodes

Manufacturers pack electrodes in sealed boxes for a reason. Electrodes tend to absorb moisture from the environment. Wet and dirty electrodes produce an erratic arc, excessive spatter, and highly unpredictable results.

To avoid these issues, always store your electrodes in their packaging and in clean, dry places. Once you break the seal, you must keep the electrodes dry and clean.

Pay special attention to low-hydrogen electrodes. Once you break the seal, low-hydrogen electrodes absorb even the slightest moisture, so you should either use them quickly or store them in a rod oven. A rod oven is specialized equipment that re-bakes the flux coating on an electrode. It evaporates any moisture and leaves electrodes ready to weld.

A Rod Oven for Re-baking the Flux Coating on Electrodes
Source: https://www.youtube.com/watch?v=OenixcCMnZc

9. Practice, Practice, Practice

Before running the welds, use the same type and thickness of scrap metal to practice and tune the machine. Run a few test beads to adjust CLAMS for best results and according to your personal preferences. As you do test welds, run the troubleshooting.

After you dial in the machine, you can do a dry run. A dry run is a run without powering the machine. Even though you are not practically welding, you can use a dry run to find a comfortable position. You will need good vision to control the weld puddle and make your body and hands comfortable throughout the run.

To practice the electrode manipulation, you can clamp the pencil in the electrode holder and use a piece of paper. This practice can be beneficial when trying to master weaving. Drawing the zig-zag, circles, or crescent weaves across the imaginary joint can significantly help you practice the stick welding technique.

Practice the Stick Welding Technique
Photo by @weldsnmore (TikTok)

Final Thoughts

Stick welding is truly a unique, strong, cheap welding method that produces solid and everlasting bonds. However, the final results can highly depend on the precautions and techniques of the welder performing the welds.

If you are a beginner, start by prioritizing safety. Stick welding might be the most hazardous method, so beware. Remember the weld preparation, which includes cleaning and aligning the pieces. Good preparation is half the work in welding.

The most critical tip for the Stick welding technique involves adjusting the CLAMS. Bringing these parameters together can make or break your project, so practice and take your time when determining what's best for your projects.