Stick welding uses a two-piece electrode with a metal alloy core and silicon-based flux to create strong welds. Moisture and incorrect heat settings cause porosity, while spatter indicates excessive heat. Proper handling and direction of the electrode ensure a structurally sound weld.
Shielded metal arc welding, also known as stick welding, uses a two-piece electrode to produce a structurally sound weld across multiple pieces of metal. The inner core of a stick electrode contains a metal alloy designed to weld a base metal of the same composition. A silicon-based flux surrounds the metal alloy and protects the molten solder from atmospheric contamination. Proper handling of the welding electrodes combined with the correct heat setting creates a strong weld with little spatter and no porosity.
Porosity consists of small holes that penetrate a weld. Moisture causes the flux of a shielded metal arc welding electrode to crack and become soft. The soft flux falls off the electrode rather than melting on the weld, allowing nitrogen in the atmosphere to react with the weld. Keeping the electrodes dry before welding reduces the amount of moisture contained in the silicon-based flux. An incorrect heat setting is a secondary cause of porosity.
The cooled flux coming off a finished weld indicates the correct amount of heat for a shielded metal arc weld bead. The increased heat causes small beads of metal called spatter to form around the weld. Throwing metal from the weld pool disrupts the protective barrier surrounding the weld, causing large pockets of porosity. Reducing the temperature eliminates spatter and porosity but reduces the amount of penetration between the stick electrode and the base metal.
A low penetration weld does not melt deeply enough into the metal to provide a structurally strong weld joint. Hitting the surface of the base flour and an electrode that won’t ignite or sticks to the metal are early signs that the welding temperature is too low. Another sign of a cold shielded metal arc welding temperature is curling in the sides of the weld bead. This makes the weld appear as if it is on top of the metal instead of being fused to the metal surface. Cold welding temperatures are not the only factor determining penetration during stick welding.
The direction of travel of the rod changes the shape and penetration during shielded metal arc welding. An electrode pulled along the surface will allow the weld to penetrate deeply and prevent molten flux from entering the weld pool. Proper heat setting and weld direction and inspection of each electrode before use will ensure that your finished shielded metal arc weld remains strong under pressure.
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