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Tips For Vertical Welding
There are four primary positions in welding: flat, horizontal, vertical, and overhead. Welders consider flat and horizontal welding straightforward, while challenges arise in overhead and vertical welding.
When welding vertically or overhead, you are fighting gravity. Gravity pulls and sags the molten weld puddle, creating various defects and faulty welds.
In this article, we will focus on issues and solutions related to vertical welding. Whether you are a beginner or a seasoned welder, these tips for vertical welding will help you improve your skills and produce sound, high-quality welds.
Stick Welding in Vertical Position
Photo by @sarahwelds_ (TikTok)
Welding Positions Explained
Welders join metal pieces in four primary positions:
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Flat
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Horizontal
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Vertical
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Overhead
Source: https://capitolironworksdc.com/blog/welding-positions
Welding in a flat position is considered the most straightforward. The pieces lay flat, and gravity pulls down the molten puddle for you. As a beginner, you should stick to a flat position whenever possible.
In a horizontal position, the two pieces are often vertical, but the weld axis is roughly horizontal. You weld on the side of the weld, and gravity can slightly pull the puddle to the lower edge of the joint.
Welders consider welding in a vertical position to be one of the most challenging. The welding axis is vertical, and gravity pulls down the molten puddle, making it difficult to control.
Welding overhead is challenging and dangerous. The molten puddle can drip on your helmet or body, causing burns. That's why most professional welders perform overhead and vertical welding.
Overhead Stick Welding Process
Photo by @jdaviddhh2.o (TikTok)
Applications And Challenges of Vertical Welding
Welders worldwide use vertical welding in various applications, the most common being construction, pipeline welding, or shipbuilding. They also use it to build new power plants, improve old ones, and repair refineries. Ironworkers, pipe fitters, boilermakers, and shipbuilders regularly weld vertically to join pipes, ship plates, and metal parts.
Vertical welding is an advanced welding position that requires more skill due to its nature. The primary challenges of vertical welding include the following:
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Hard to control puddle: The gravity pulls the weld puddle down the joint, making it highly challenging to maintain, especially for beginners. Poor puddle control can cause a lack of fusion or penetration.
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Poor bead appearance: Failure to control the puddle properly can yield uneven beads with a poor appearance. A lack of control can also impact weld aesthetics and structural integrity.
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Potentially harmful: Overfluid weld puddle can drip down on your pants or feet. High amperage can also cause a lot of hard spatter that requires more time to clean up.
Spatter in Vertical Stick Welding
Source: https://www.youtube.com/watch?v=2JJxuwZ055A&t=125s
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Compromised welds: Failing to adapt to vertical welding can produce various weld defects, such as undercutting, porosity, lack of fusion, or penetration.
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High skill requirements: Vertical welding is challenging and often performed by seasoned welds.
To address and overcome the issues of vertical welding, you will need the right tools, techniques, and knowledge. The following tips and tricks can help you understand the basics of vertical welding.
Source: https://www.youtube.com/watch?v=EfXwtAs7LlQ
Do You Weld Vertically Up or Down? (Vertical Up vs Vertical Down)
There are two ways to perform vertical welds. You can either start from the bottom of the joint and move towards the top (Vertical up) or start from the top of the joint and move downwards (Vertical down).
Source: http://www.tpub.com/steelworker1/70.htm
Many welders prefer vertical up welding or welding from the bottom to the top of the joint. Although this method is slower, the arc melts the base metal, providing better penetration and control over the weld puddle. Due to improved penetration, most welders use vertical up welding to join anything other than thin sheet metals in a vertical position.
Welding vertically down can be tricky, as gravity already pulls down and stretches the puddle before it solidifies. Although much faster than vertical up, the heat input in vertical down is reasonably limited. Thus, using it on thinner metals can yield a lack of penetration and fusion. However, welders occasionally use vertical down when fusing thin sheet metal. The limited heat input and fast speeds prevent the warping and distortion of sheets and delicate metals.
Stick Welding Vertically Down
Photo by @biswajeetrwtikgp (YouTube shorts)
Vertical Welding Methods
You can weld vertically with any of the four most popular arc welding methods: MIG welding, Stick welding, TIG welding, or Flux-cored arc welding.
Each welding process has advantages and disadvantages and has more dedicated applications, so let's explore them further.
Vertical Stick Welding
Source: https://www.youtube.com/watch?v=2Sv3f4NErnc&t=18s
Vertical MIG Welding
Welders consider MIG welding to be one of the most straightforward welding methods. Its popularity among beginners comes from its semi-automated nature, which makes it highly convenient to operate.
However, welding vertically, even with Gas Metal Arc Welding (GMAW), can be a challenging task. To get the best results, you will need to tune down the welder, adjust the technique, and use the right tools for the job.
The goal is to produce a puddle that is neither too fluid nor too hot. The technique adjustments should affect your ability to see and control the puddle as you run. Here are some more detailed explanations.
Vertical MIG Welding Process
Source: https://www.youtube.com/watch?app=desktop&v=dFd6MfcfRiE
Adjusting The Parameters For Vertical MIG
When setting up your MIG welder for vertical welding, you should tune down the voltage and wire feed speed. Reducing the heat by 10-15% for the recommended metal thickness will promote fast freezing and puddle cooling.
Reducing fluidity and promoting freezing are crucial in controlling the weld puddle. Controlling allows you to fill the joint, promote the sidewall fusion, and avoid undercutting. Fast freezing will prevent the puddle from escaping or dripping down the joint, helping you produce cleaner, safer, and higher-quality welds.
However, be cautious when reducing the heat. If you lower the voltage and wire feed speed too much, you might not be able to penetrate the pieces. Although your bead sits appropriately inside the joint, it might not yield proper penetration.
Thus, the final goal is to reduce the heat to the point where your weld doesn't fall out of the joint but still penetrates appropriately. For beginners, this might involve trial and error. But once you get the heat right, you are set for success.
MIG Welding Vertical Up
Source: https://www.youtube.com/shorts/X7RXopa3nEM
Adjusting The Technique For Vertical MIG
After tuning down the heat, you should adjust the technique for vertical MIG welding. There are several things you can do to avoid undercutting and provide good sidewall fusion in vertical MIG.
You should shorten the stickout. For beginners, a stickout is the wire distance between the contact tip and the puddle. By reducing the stickout to 1/2" or shorter, you provide adequate arc force. The arc force will help the puddle penetrate the pieces and not pile up too much.
Also, be aware of the gun angle. Try to use a 90-degree gun angle while still being able to see and control the puddle. Even though the nozzle can block your view, you can slightly lean the gun for 5 degrees while still being able to produce sound welds.
Torch Angle of Vertical MIG Welding
Source: hhttps://www.youtube.com/watch?v=CPvwecz1dAk&t=67s
Weave the bead for the best results. Vertical MIG welding often requires weaving the torch from side to side. Most welders prefer triangle beads. With triangle or reverse V weaving beads, you start on one side of the joint and move your way up by drawing the triangles with a torch.
When weaving, you provide proper fill-in and sidewall fusion in vertical MIG. Additionally, you evenly distribute the heat around the joint, rather than focusing it in one point, like with stringer beads. As a result, you avoid excessive reinforcement and heat build-up.
The final goal of adjusting the technique for vertical MIG welding is to keep the arc on the front of the puddle while weaving your way up the joint. Altering the technique is key to making sound MIG welds in vertical welding.
MIG Weld Vertical Up
Photo by @ryanhutchinson32 (TikTok)
Equipment Considerations
The good side of vertical MIG is that you don't need any specialized equipment to do it. However, some pieces can make your welding easier.
The YesWelder DP200 is a dual-pulsed MIG welder that can help you with aluminum MIG welding. The heat limit of pulsed welding can also be helpful in vertical welding, especially on thin and delicate pieces, so you should strongly consider it.
Firstess DP200 Multi-Process MIG Welder
Additionally, you can check the MIG gun nozzle/contact tip setup. Using a contact tip that is flush with the nozzle instead of recessed can help you weld with a shorter stickout, which is necessary for vertical MIG welding.
Tips For Vertical MIG Welding
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Reduce the voltage and wire feed speed for the given material thickness to promote faster freezing and better control.
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Try not to overturn the heat to the point where you don't get proper penetration.
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Reduce the wire stickout to 1/2" or shorter to provide adequate arc force.
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Try to use a 90-degree MIG gun angle while maintaining a good vision over the puddle.
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Use a weaving bead such as triangles or an upside-down V technique to provide good sidewall fusion and prevent heat build-up.
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Keep the arc on the front of the puddle.
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Try to use a contact tip that is flush with a nozzle to reduce the stickout length.
While MIG welding vertically, use a contact tip flush with the nozzle and keep the wire stick out at 1/2” or shorter.
Photo by @weldingmigstick (TikTok)
Vertical Stick Welding
Welders use vertical Stick welding in industries across the globe. This method is a backbone of structural, pipeline, and construction sectors, where it finds various applications.
Skill-wise, many welders find Stick welding more challenging than MIG. Welding vertically adds the skill requirements, so this technique is often reserved for seasoned welders, and it requires a proper certification to run.
But for your home, hobby, and DIY vertical Stick applications, you can get away by reading the following tips.
Stick Vertical Welding Process
Photo by @tht.5.3 (TikTok)
Choose The Right Electrode For Vertical Stick Welding
Stick electrodes are a central piece of Shielded Metal Arc Welding. Choosing the right one can significantly improve vertical Stick welding.
To battle gravity in vertical welding, you should use fast-freezing electrodes such as E7018 or E6010. Most welders prefer E7018 electrodes due to their low iron powder content. The molten metal forms a fast-freezing puddle, which is less likely to drip or fall out from the joint during vertical welding.
E6010 electrodes produce similar results and are excellent for welding dirty or rusty surfaces. However, they require a whipping or stacking technique, which is slower and more complicated than zig-zag weaving with E7018.
If you are new to vertical welding, we recommend starting with E7018s. Avoid using E7024s, as they can uncontrollably drip down the joint.
Start Vertical Welding with E7018 Rods
Photo by @yourweldingcoach (TikTok)
Reduce The Amperage For Vertical Stick Welding
Similar to MIG welding, you should reduce the power on your Stick welder by 10-15% to promote faster freezing. The sooner the puddle freezes, the less likely it will sag or drip down the joint.
Therefore, when Stick welding vertically, tune the power down to the lower end of an electrode's amperage rating. For example, a 1/8-inch E7018 electrode typically handles 110-165 amps, while the same-sized E6010 commonly uses 75-125 amps.
When Stick welding vertically with 1/8-inch E7018, tune the amps to approximately 120-130 amps. Meanwhile, you should run 1/8-inch E6010 at 90-100 amps. You can add up to 5% more amperage when welding on dirty surfaces.
The Weld Puddle when Vertical Stick Welding with 1/8-Inch E7018 at 120-130 Amps (125 Amps in the Photo)
Source: https://www.youtube.com/watch?v=2ouOhP9DceM
Push The Electrode When Stick Welding Vertically
Welders commonly use Shielded Metal Arc Welding to join medium-to-thick pieces. As a result, you should perform most of your vertical Stick welding from the bottom to the top of the joint or vertically up.
Stick Welding Vertical Up
Photo by @surgicalwelds (TikTok)
The golden rule of flux welding methods, including Stick/Arc welding is: If there is a slag, you must drag. However, the only exception is Stick welding vertically up, where you should push the electrode. If you try to pull the electrode up, the weld won't stay or penetrate the joint for too long. Although pushing the torch up takes more time, it produces proper penetration and good heat input into the joint.
Try to maintain a tight arc angle as you push the electrode up the joint. A tight arc allows you to control the puddle better and reduces the voltage. Lower voltage reduces the overall heat and helps the puddle solidify faster. However, keep in mind that an arc that is too tight may cause the electrode to stick to the base metal.
Start welding by placing your electrode at a 90-degree work angle or perpendicular to the joint. Then, tilt the electrode to the 10-15 degrees travel angle, which you would ordinarily use in a horizontal position. Adjust the travel angle as you move to ensure proper control and vision over the weld, but try not to exceed the recommended 10-15 degrees.
Electrode and Travel Angle for Vertical Stick Welding
Weave The Electrode
Similar to MIG welding, vertical Stick welding requires weaving the electrode along the joint. When weaving vertically up, you create a weld shelf that supports the following welds, preventing them from falling out or sagging from the joint.
Thus, Stick welding vertically up is quite similar to bricklaying. You create the weld base from the bottom to the top, slowly progressing one small section at a time. By doing so, you produce proper penetration and weld control while reducing the risks of weld dripping.
Build the weld from bottom to top, progressing in small sections.
Source: https://www.youtube.com/watch?v=csS_q2Q-p98
Weave patterns will mostly depend on the electrode choice. For example, E7018s support zig-zagging, triangles, or upside-down V techniques. Generally, you can weave faster compared to E6010s. Make sure you start and spend enough time on the sides to distribute the heat evenly, provide good sidewall fusion, and prevent undercutting.
Stick welding vertically with E6010 electrodes requires a whipping technique or stacked chips. This is an advanced welding method in which you start from one side to the other. Once you reach the end, remove the rod from the weld crater, but do not break the arc. Then, move to the other side, remove it, rinse, and repeat. The motion feels like whipping, and the weld looks like stacked poker chips.
Stick welding thick stock, such as pipes, requires multi-pass welding. If the pieces require multi-pass vertical welding, use box or Z weaving motion, with pauses for proper filler distribution. Clean the slag after each pass to avoid slag inclusions that can cause critical weld failure.
Take Your Time
Stick welding vertically up is all about patience and good preparation. The process is slower than horizontal Stick welding, so do not rush. Rushing can cause the weld to fall out and drip down, and you'll need to start again. Losing the weld requires more downtime and rework, increasing the overall welding costs.
Also, take your time choosing the right equipment and preparing the welds. We recommend YesWelder Arc205DS Pro as a capable welder for vertical Stick welding. Prepare, align, and clamp the pieces to ensure an even weld. Take your time to dial in the machine and get the best results.
ARC-205DS-PRO Digital Display 110V/220V Stick& Lift TIG In One Stick Welder
Vertical Stick Welding Tips
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Use fast-freezing electrodes such as E7018 or E6010.
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Avoid using E7024 as they drip uncontrollably.
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Use 10-15% less amperage than you usually would.
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Turn to the lower end of the electrode's amperage rating.
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Push the puddle rather than pull.
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Weld from the bottom to the top (vertically up) for the best penetration on thicker pieces.
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Avoid welding vertically down anything other than thin sheets.
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Use the 90-degree work angle and 10-15 degrees travel angle.
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Weave the electrode across the joint.
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Do not rush during the welding and in weld preparation.
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Consider flux-cored arc welding as an alternative.
Flux-cored Vertical Welding
Photo by @weldfools (TikTok)
Vertical TIG Welding
Many welders consider TIG welding to be one of the most challenging welding methods. It takes a lot of time and skill to master, but it yields some of the highest-quality results.
Welders typically use TIG welding to weld thin pieces of stainless steel and non-ferrous metals such as aluminum, magnesium, and copper alloys. However, those pieces can occasionally be placed vertically and require vertical welding. Although not that common, vertical TIG is often used when welding sanitary, thin pipes and vessels.
In general, vertical TIG welding is not very different from ordinary flat TIG welding. Here are several tips and tricks for vertical TIG welding.
TIG Vertical Welding Tips
Photo by @welder_yan (TikTok)
Tips for Vertical TIG Welding
Welders mostly use TIG welding to weld thin gauges down to 22 ga., so you'll need a reliable welder such as YesWelder TIG200 AC/DC Pro. Since thin pieces already need low amps, you don't need to reduce the power further to promote faster freezing.
TIG-200P-ACDC-PRO AC/DC Aluminum TIG Welder
Even though vertical down provides less heat impact on thin pieces, most welders prefer to TIG weld vertically up. The heat limit of the process itself allows welders to weld upwards without warping or distorting the pieces while providing adequate penetration.
When moving up the joint, keep the tungsten at a right angle with the workpiece. The tip of the electrode can point slightly toward the top of the joint. Dip the rod right above it at the leading edge of the weld puddle.
As you move, make sure you can see your arc and feed the rod. Failing to do any of these two can greatly impact your ability to control the puddle, causing it to drip down the joint. Take your time, as rushing may cause you to lose the weld.
TIG Vertical Welding Process
Photo by @ryanhutchinson32 (TikTok)
Conclusion
Vertical welding is an advanced but highly valuable welding technique. Although it takes more time and skill to master than welding in a flat position, the results are satisfying.
To successfully weld in a vertical position, you must address the primary concern: gravity. Gravity pulls the molten filler metal down, causing it to drip down or sag from the joint, creating weak welds.
Dealing with gravity requires reducing the heat to promote faster weld puddle freezing. To achieve proper penetration, you weave the torch to create a foundation for the following welds. Once you get everything right, you can weld vertically in nearly all situations and welding applications.
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