Stick Welding: Which Type of Welding Is It Exactly?

Stick welding is one of the oldest and most widely used welding methods in the world, yet many people still wonder exactly which category of welding it belongs to. Whether you are a beginner welder, a DIY enthusiast, or someone researching for a project, understanding where stick welding fits in the broader welding landscape is essential for choosing the right technique. Stick welding is classified as Shielded Metal Arc Welding (SMAW), a process that uses a consumable electrode coated in flux to create the weld joint.

This post breaks down exactly which type of welding stick welding is, how it works, what electrodes you need, and how it compares to other popular welding methods. By the end, you will have a clear picture of stick welding and whether it is the right approach for your needs.

Simply put, stick welding is a type of arc welding known as Shielded Metal Arc Welding (SMAW). It uses a flux-coated consumable electrode to join metals through an electric arc, making it versatile enough for steel, iron, and even some stainless steel applications.

Key Takeaways

• Stick welding is formally known as Shielded Metal Arc Welding (SMAW), a subset of arc welding.
• It uses a consumable electrode coated in flux that shields the weld pool from atmospheric contamination.
• Stick welding works on a wide range of metals including carbon steel, stainless steel, cast iron, and certain alloys.
• The process is highly portable and performs well in outdoor and windy conditions where other methods struggle.
• Learning proper electrode selection and technique is key to producing clean, strong welds with this method.

What Type of Welding Is Stick Welding?

Stick welding falls under the category of arc welding. More specifically, it is classified as Shielded Metal Arc Welding, commonly abbreviated as SMAW. The American Welding Society (AWS) recognizes SMAW as one of the primary fusion welding processes used across industrial, construction, and maintenance applications worldwide.

Arc welding is a broad family of welding processes that use an electric arc to melt and join metals. Within that family, SMAW stands out because of its simplicity and self-contained nature. Unlike MIG welding or TIG welding, stick welding does not require a separate shielding gas cylinder.

The flux coating on the electrode does all the shielding work, which is what makes the process so portable and practical.

As the table shows, stick welding sits firmly within the arc welding family. It was developed in the early 1900s and has remained one of the most commonly used welding processes ever since. The National Board of Boiler and Pressure Vessel Inspectors notes that SMAW is still one of the most specified welding processes in code-construction work across the United States.

How Does Stick Welding (SMAW) Work?

Understanding how stick welding works starts with knowing the basic components. The process requires a welding machine (power source), a ground clamp, and a consumable electrode. The electrode is a metal rod coated in a chemical flux, which is why it is colloquially called a “stick” – it looks like a coated stick you hold in an electrode holder.

When you strike the electrode against the workpiece, it creates an electric arc between the electrode tip and the base metal. This arc generates temperatures around 6,500 degrees Fahrenheit (3,600 degrees Celsius), which is hot enough to melt both the electrode and the base metal simultaneously. The molten metals fuse together to form the weld joint.

The flux coating serves a critical purpose. As it burns, it produces a shielding gas that protects the molten weld pool from oxygen and nitrogen in the air. Without this shielding, the weld would be porous, weak, and full of defects.

The flux also leaves behind a layer of slag on top of the finished weld that must be chipped away with a chipping hammer.

The Step-by-Step SMAW Process

1. Set up your equipment – Connect the ground clamp to the workpiece and load the electrode into the holder.
2. Select the right amperage – Adjust your machine based on electrode diameter and metal thickness.
3. Strike the arc – Scratch or tap the electrode against the metal to initiate the arc, similar to striking a match.
4. Maintain proper arc length – Keep the electrode at a consistent distance from the workpiece, roughly equal to the electrode diameter.
5. Travel along the joint – Move the electrode along the weld line at a steady pace, using the correct angle.
6. Remove the slag – Once the weld cools, chip off the protective slag layer to reveal the weld bead underneath.

According to the Lincoln Electric Company, the world’s largest manufacturer of welding products, proper arc length control is the single most important skill for producing quality SMAW welds. An arc that is too long causes porosity and spatter, while an arc that is too short can cause the electrode to stick to the workpiece.

This component breakdown shows why stick welding is so self-sufficient. There is no gas bottle to carry, no wire spool to feed, and no complex machine settings to navigate. That is exactly why it remains a top choice for field work and maintenance repairs.

What Are the Main Types of Stick Welding Electrodes?

One of the most important aspects of stick welding is choosing the right electrode. The electrode determines the type of metal you can weld, the position you can weld in, and the overall quality of the finished joint. The AWS classifies stick welding electrodes using a numbering system that tells you almost everything you need to know about that electrode’s capabilities.

The most common classification is the E6010, E6011, E6013, and E7018 electrodes. The “E” stands for electrode, the first two or three digits indicate the minimum tensile strength in thousands of pounds per square inch, and the final two digits specify the coating type and welding positions.

• E6010 – Deep penetrating electrode with a cellulose sodium coating. Best for root passes on pipe and structural steel. Works on DC only.
• E6011 – Similar to E6010 but works on both AC and DC. Great for outdoor use and rusty or dirty metal.
• E6013 – Soft arc with shallow penetration. Ideal for thin sheet metal and light-gauge materials. Easy for beginners.
• E7018 – Low hydrogen electrode producing high-strength welds. The industry standard for structural steel and code-required work.
• E7024 – High deposition rate electrode with a iron powder coating. Excellent for flat and horizontal positions on thick material.

Tip: If you are just starting with stick welding, begin with E6013 electrodes. They run on both AC and DC, produce minimal spatter, and are very forgiving of inconsistent technique.

The American Institute of Steel Construction (AISC) requires E7018 or equivalent low-hydrogen electrodes for most structural steel connections. This makes E7018 the electrode you will encounter most often in professional construction and fabrication settings.

How Does Stick Welding Compare to MIG and TIG Welding?

When people ask which type of welding is stick welding, they often want to understand how it stacks up against other popular methods. The three most common arc welding processes are SMAW (stick), GMAW (MIG), and GTAW (TIG). Each has its own strengths and ideal use cases.

MIG welding uses a continuous wire feed and an external shielding gas to create the weld. It is faster and easier to learn than stick welding, making it the go-to choice for automotive repair and sheet metal fabrication. However, MIG welding struggles outdoors because the wind can blow away the shielding gas before it reaches the weld pool.

TIG welding produces the cleanest, most precise welds of any arc welding process. It uses a non-consumable tungsten electrode and an separate filler rod, giving the welder complete control over heat input and filler deposition. The downside is that TIG is slow, requires two hands, and demands a very high skill level.

This comparison makes it clear that stick welding occupies a practical middle ground. It is more versatile than MIG for outdoor and heavy-duty work, and far more accessible than TIG for everyday fabrication and repair tasks.

What Are the Advantages and Disadvantages of Stick Welding?

Every welding process has tradeoffs, and stick welding is no exception. Knowing the advantages and limitations helps you decide when SMAW is the right choice and when you should reach for a different process.

Advantages of Stick Welding

• Extremely portable – A basic stick welding machine weighs as little as 10-20 pounds and requires only a standard electrical outlet or generator.
• Works outdoors – The flux coating creates its own shielding environment, so wind and weather have minimal effect on weld quality.
• Handles dirty metal – E6010 and E6011 electrodes can burn through rust, paint, dirt, and light corrosion without extensive cleaning.
• Wide metal range – You can weld carbon steel, stainless steel, cast iron, and many alloys with the right electrode selection.
• Low equipment cost – A quality stick welder costs less than most MIG or TIG setups, and there are no ongoing gas expenses.
• Thick material capability – SMAW can join very thick sections of steel using multiple passes, making it ideal for structural and heavy fabrication work.

Disadvantages of Stick Welding

• Electrode replacement – You must stop and replace the electrode each time it is consumed, which interrupts the workflow.
• Slag removal required – Every pass produces a slag layer that must be chipped and wire-brushed before the next pass or inspection.
• Steeper learning curve – Maintaining consistent arc length and travel speed takes more practice than MIG welding.
• Less suitable for thin metal – The high heat input can burn through thin sheet metal without careful amperage control.
• Spatter production – Stick welding generally produces more spatter than MIG, requiring additional cleanup.

The Welding Journal reports that SMAW still accounts for a significant share of all welding performed in construction, shipbuilding, and pipeline industries. Despite newer technologies, the advantages of stick welding keep it relevant and necessary.

Where Is Stick Welding Used in Real-World Applications?

Stick welding is used across a surprising range of industries and applications. Its versatility and portability make it the preferred method whenever conditions are less than ideal or when the workpiece is too large or immovable to bring into a shop environment.

• Construction and structural steel – Bridges, buildings, and steel frameworks rely heavily on SMAW for field connections and repairs.
• Pipeline welding – Oil and gas pipelines use SMAW for root passes because the deep penetration and outdoor capability are unmatched.
• Shipbuilding and marine repair – The ability to weld in confined spaces and in humid conditions makes SMAW valuable in shipyards.
• Maintenance and repair – Farm equipment, heavy machinery, and industrial equipment often get repaired with stick welding due to its simplicity.
• Power plant construction – Boiler tubes and pressure vessel work frequently specify SMAW processes per ASME codes.
• Agricultural equipment – Farmers and ranchers commonly use portable stick welders for fence repair, implement fixes, and general metalwork.

According to the U.S. Bureau of Labor Statistics, approximately 65,000 welders, cutters, solderers, and brazers are employed across the United States, with many of these professionals using SMAW as part of their daily work routine. The versatility of the process ensures steady demand for skilled SMAW operators.

The process also has a strong presence in developing nations and remote locations where access to shielding gas and specialized equipment is limited. A simple diesel or gasoline-powered stick welder can operate almost anywhere, which is why SMAW remains the welding method of choice in many parts of the world.

What Are Common Mistakes Beginners Make with Stick Welding?

Learning stick welding comes with a learning curve, and beginners tend to make several predictable mistakes. Recognizing these errors early saves time, material, and frustration as you develop your skills.

1. Holding too long an arc – Beginners often pull the electrode too far from the workpiece, causing excessive spatter, porosity, and a wide, flat bead. Keep the arc tight, roughly the diameter of the electrode core wire.
2. Wrong amperage setting – Starting too high causes burn-through and excessive spatter. Starting too low causes the electrode to stick and the arc to extinguish. Start at the manufacturer’s recommended amperage and adjust from there.
3. Ignoring travel speed – Moving too fast produces a thin, stringy bead with poor fusion. Moving too slow creates a wide, humped bead that traps slag inclusions.
4. Not cleaning between passes – Failing to remove slag between weld passes causes slag inclusions that weaken the joint. Always chip and brush every pass.
5. Poor joint preparation – Skipping grinding or cleaning of the base metal leads to contamination and poor fusion. Even E6010 electrodes perform better on clean metal.
6. Wrong electrode angle – The ideal drag angle is 5 to 15 degrees from perpendicular in the direction of travel. Pointing the electrode too far forward or backward affects penetration and bead shape.

Important: Practice on scrap metal before welding your actual project. Set up several flat butt joints on 1/8-inch and 1/4-inch steel plate to get comfortable with arc striking, puddle control, and travel speed.

The Hobart Institute of Welding Technology, one of the leading welding schools in the United States, emphasizes that most beginner mistakes stem from trying to rush the learning process. Taking time to master the fundamentals produces dramatically better results over a shorter period.

How Do You Choose the Right Stick Welding Machine?

Selecting a stick welding machine depends on your intended applications, power availability, and budget. The market offers everything from small portable inverter units to large industrial transformer-based machines. Understanding the key specifications helps you make the right choice.

• Amperage range – Most common stick electrodes run between 50 and 200 amps. Choose a machine that covers this range at minimum.
• Duty cycle – A 20% duty cycle at 150 amps means you can weld for 2 minutes out of every 10. Higher duty cycles matter for extended production work.
• AC/DC capability – DC welding provides smoother arcs and better performance. AC-only machines limit your electrode choices and overall versatility.
• Power requirements – Some machines run on 120V household outlets, while others need 230V or three-phase power. Match the machine to your available power.
• Portability – Inverter-based stick welders can weigh under 20 pounds, making them ideal for mobile work and field repairs.
• Brand reliability – Reputable manufacturers like Lincoln Electric, Miller Electric, ESAB, and Hobart have proven track records for durability and support.

A report from Grand View Research valued the global welding equipment market at over $12 billion, with inverter-based machines representing the fastest-growing segment. These modern units deliver better arc performance in a smaller, lighter package compared to traditional transformer machines.

Tip: If you can only afford one stick welder, look for an AC/DC inverter unit with at least 200 amps output and a 30%+ duty cycle. This gives you the flexibility to run any electrode and handle most common projects.

What Safety Precautions Should You Follow When Stick Welding?

Safety is non-negotiable when performing stick welding. The process generates intense ultraviolet and infrared radiation, flying sparks, toxic fumes, and extreme heat. Following established safety protocols protects you and those around you.

• Eye protection – Use an auto-darkening or fixed-shade welding helmet rated at shade 10 to 13. Regular safety glasses should be worn under the helmet.
• Skin protection – Wear flame-resistant long-sleeve shirts, welding gloves, and leather aprons. Exposed skin can suffer arc burn within seconds of exposure.
• Respiratory protection – Welding fumes contain manganese, hexavalent chromium, and other hazardous compounds. Use a NIOSH-approved respirator or ensure adequate ventilation.
• Fire prevention – Clear the area of flammable materials within 35 feet. Keep a fire extinguisher within arm’s reach at all times.
• Electrical safety – Never weld in standing water or wet conditions. Inspect electrode holders, cables, and ground clamps for damage before each use.
• Ear protection – The cracking sound of the arc can exceed 100 decibels. Use earplugs or earmuffs to prevent hearing damage.
• Helmet settings – Adjust your helmet shade based on amperage. Higher amperage requires a darker shade to prevent eye strain and retinal damage.

The Occupational Safety and Health Administration (OSHA) mandates specific safety standards for welding operations under 29 CFR 1910.252. These standards cover ventilation requirements, fire watch protocols, and personal protective equipment specifications that every stick welder must understand and follow.

Frequently Asked Questions

What is the difference between stick welding and arc welding?

Stick welding IS a type of arc welding. Specifically, stick welding is called Shielded Metal Arc Welding (SMAW), which is one of several arc welding processes. Other arc welding processes include MIG (GMAW) and TIG (GTAW), but stick welding was the original arc welding method developed.

Can stick welding be used on stainless steel?

Yes, stick welding works on stainless steel, but you need the correct electrode. Use electrodes specifically designed for stainless steel, such as E308L-16 or E316L-16. These electrodes maintain the corrosion-resistant properties of stainless steel and produce clean, sound welds when used with proper technique.

Is stick welding good for beginners?

Stick welding can be challenging for beginners due to the need for arc length control and technique. However, it is also an excellent foundational skill because it teaches you puddle awareness, heat control, and joint preparation. Many experienced welders recommend starting with E6013 electrodes, which are the most forgiving.

How thick of metal can you weld with stick welding?

Stick welding can handle metal from about 16 gauge up to several inches thick. For steel plate, single-pass welds work well on material from 3/16 inch to 1/2 inch thick. Multiple passes allow you to weld sections several inches thick, which is common in heavy fabrication and structural applications.

What is the best stick welding electrode for general use?

The E7018 is the most versatile and widely used electrode for general structural steel welding. It produces high-quality, high-strength welds and meets most code requirements. For a beginner-friendly option, E6013 is easier to run and more forgiving of technique errors, making it a great choice for learning and light-duty work.

Final Thoughts

Stick welding is a type of arc welding known as Shielded Metal Arc Welding (SMAW), and it remains one of the most versatile, portable, and widely used welding processes available today. From structural steel construction to farm equipment repair, SMAW delivers reliable results in conditions where other processes fall short. Whether you are a beginner learning the craft or an experienced welder expanding your skillset, understanding stick welding gives you a powerful tool in your metalworking arsenal.

Focus on electrode selection, arc control, and safety, and you will produce strong, professional-quality welds with this time-tested process.