Stick welding is a manual arc welding process that uses welding sticks made of filler metal and flux to join two pieces of metal together. It is a simple and low-cost method commonly used in pipeline construction, automobile repair, steel building construction, and industrial fabrication. Stick welding is versatile and can be used on various metals, including iron, steel, aluminum, copper, and nickel alloys. Its main disadvantage is welding spatter, but it is still adequate for many industrial and domestic welding applications.
Stick welding is an arc welding process that uses welding sticks, also called welding rods. This process is also known as manual arc welding or shielded metal arc welding. Weld sticks are composed of filler metal and flux. The flux component is used to protect the molten metal of the weld while the filler metal is used to join two pieces of metal together.
The equipment and method used in this process is very simple. A work lead is attached to the work piece and connected to one side of an arc welding power supply. The electrode cable and electrode holder are connected to the other side of the power supply. The consumable welding stick is placed in the electrode holder and is used as an electrode, closing the power circuit. When this circuit is closed, the electrical resistance of the workpiece’s base metals and filler metal create the large amounts of heat needed for welding.
To start the stick welding process, the electrode is struck rapidly against the workpiece to create an electric arc. This step is called hitting a bow. By moving along the joint and maintaining close proximity to the electrode and workpiece, a long, continuous weld can be made. Once welded and allowed to cool, the slag created by the protective action of the flux is driven off using a slag hammer. The joint is then ready for finishing or further welding.
Due to ease of use and low operating costs, stick welding is one of the most common industrial welding processes. While it is primarily used to weld base metals such as iron and steel, there are many other metals that can be joined using this process. Some of these other metals include aluminum, copper and nickel alloys. These other metals may require special welding sticks to avoid problems with incompatible metals in a weld.
The stick welding method is commonly used in pipeline construction, automobile repair, steel building construction and industrial fabrication. With the versatility of the methods and the low cost of the equipment, it has also found a place in home workshops. The main disadvantage of using this welding method is welding spatter. This occurs when pieces of molten metal adhere to areas outside the joint. While the stick welding technique does not produce the clean welds of laser welding processes, it is more than adequate for many industrial and domestic welding applications.
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