Stick Welding (SMAW) Explained: What It Is, How It Works & When to Use It
Stick welding — formally known as Shielded Metal Arc Welding (SMAW) — is one of the oldest, most rugged, and most widely used welding processes in the world. From pipeline construction and structural steel to heavy equipment repair and field maintenance, stick welding earns its place on demanding job sites because it works in conditions that would sideline other processes. This guide covers how SMAW works, when to use it, how to select electrodes, and how it stacks up against MIG and flux core.
What Is Stick Welding (SMAW)?
Stick welding is an arc welding process that uses a consumable flux-coated electrode — the "stick" — to create the weld. When the electrode contacts the base metal and an arc is struck, three things happen simultaneously: the electrode's steel core melts and deposits filler metal into the joint; the flux coating burns and generates a shielding gas that protects the molten weld pool from atmospheric oxygen and nitrogen; and a slag layer forms over the cooling bead, providing additional protection and helping shape the bead profile.
Unlike MIG welding or flux core welding, which feed wire continuously from a spool, stick welding uses individual electrodes that are manually replaced when consumed. Each electrode is typically 9" to 18" long and is held in an electrode holder (stinger) connected to the welder. Equipment requirements are minimal: a power source, electrode holder, work clamp (ground cable), and the electrodes themselves. That simplicity is one of the main reasons SMAW has remained in heavy industrial use for over a century.
Stick welding can run on AC (alternating current) or DC (direct current), depending on the machine and electrode type. DC provides a more stable arc and is preferred for most structural and pipe welding. AC is useful for certain electrode types and for welding magnetized steel where arc blow is a problem.
What Is Stick Welding Used For?
SMAW's tolerance for tough conditions makes it a workhorse across heavy industry:
- Structural steel: Building frames, bridges, and infrastructure — stick is an AWS D1.1-approved process trusted for structural welds in steel construction.
- Pipeline welding: Root passes and fill passes on pipe in the field, where portability and outdoor performance are non-negotiable.
- Heavy equipment repair: Field repairs on excavators, cranes, agricultural equipment, and industrial machinery where a gas bottle isn't practical.
- Shipbuilding and marine fabrication: Thick steel plate welding in environments where wind and humidity are constant factors.
- Construction and erection: Welding structural connectors, rebar dowels, and steel connections on active construction sites.
- Industrial maintenance: Production maintenance in plants, mills, and facilities where quick response matters more than pristine conditions.
- Outdoor and windy environments: Unlike MIG, which requires external shielding gas that wind disrupts, stick welding's self-shielding electrode performs reliably in open air.
How to Stick Weld: A Step-by-Step Overview
Step 1: Select Your Electrode
AWS electrode classifications tell you everything you need to know. For mild steel, the most common choices are:
- E6010: DC+ only, deep penetration, excellent for root passes on pipe. Demanding technique but highly capable.
- E6011: AC or DC, similar to E6010 but more versatile. Good for dirty or rusty base metal.
- E6013: AC or DC, easy arc starts, smooth bead — the most beginner-friendly option for general fabrication on clean metal.
- E7018: DC+, low-hydrogen, required for most structural and high-strength applications. Must be stored in a heated rod oven to prevent moisture absorption.
Step 2: Set Your Amperage
A reliable starting rule: approximately 1 amp per 0.001" of electrode diameter. A 1/8" (0.125") electrode typically runs 90–130 amps depending on position and base metal thickness. Always consult the manufacturer's data sheet — Lincoln Electric, ESAB, and Miller publish detailed welding parameters for every electrode in their lineup.
Step 3: Prepare the Base Metal
Clean the weld zone. Remove mill scale, rust, paint, oil, and moisture with a grinder or wire brush. Stick tolerates contamination better than MIG or TIG, but cleaner metal still produces cleaner welds with less porosity and fewer defects.
Step 4: Strike and Maintain the Arc
Use a scratch start (drag across the metal like striking a match) or a tap start (briefly touch and lift). Once the arc is established, maintain a consistent arc length roughly equal to the electrode diameter. Too long causes spatter and porosity; too short causes the electrode to stick.
Step 5: Control Travel Speed and Electrode Angle
Hold the electrode at a 15–20° drag angle (tilted in the direction of travel). Move at a steady pace that produces a bead approximately 2–3 times the electrode diameter in width. Watch the trailing edge of the weld pool — not the arc — to monitor penetration and bead shape.
Step 6: Chip Slag and Inspect
After each pass, chip off the slag with a chipping hammer and brush clean with a wire brush. Inspect for consistent width, smooth profile, and absence of porosity, undercut, or overlap. Code welds must meet the requirements of the applicable standard (AWS D1.1, ASME Section IX, API 1104, etc.).
Stick Welding vs. MIG vs. Flux Core
| Stick (SMAW) | MIG (GMAW) | Flux Core (FCAW) | |
|---|---|---|---|
| Shielding | Electrode flux coating | External gas bottle | Flux in wire core (or gas) |
| Outdoor performance | Excellent | Poor (gas disrupted by wind) | Good (self-shielding wire) |
| Learning curve | Moderate | Easiest | Easy–Moderate |
| Equipment cost | Lowest | Moderate | Moderate |
| Best material thickness | 3/16"+ (thicker material) | 24 gauge to 1/2"+ | 1/8" to 1" |
| Post-weld cleanup | Slag removal required | Minimal — no slag | Slag removal required |
For a deeper look at MIG, see our complete MIG welding guide. For flux core, see our flux core welding overview. For a direct comparison, see our full welding equipment selection.
Stick Welding FAQs
Stick has a moderate learning curve — more demanding than MIG but more forgiving of surface conditions and fit-up. The main skills to develop are arc striking, maintaining consistent arc length, and controlling travel speed and electrode angle. Most people can produce acceptable flat-position welds within a few practice sessions. Out-of-position welding (vertical, overhead) takes longer to master. The process's tolerance for dirty metal makes it particularly practical for repair and field work where material prep is limited.
Lincoln Electric, ESAB, and Miller are the three names that dominate professional stick welding. Lincoln Electric's Invertec and Flextec series are standards on structural and pipe jobs. ESAB's Rebel and Warrior series are trusted across industrial and construction applications. Miller's Maxstar line is widely used in maintenance and fabrication environments. For heavy-duty production use, look for machines with a high duty cycle (at least 60% at rated amperage) and DC output capability. Midland Tool stocks all three brands — browse our welder selection.
For mild and low-alloy structural steel, E6010, E6011, E6013, and E7018 cover most applications. E6013 is beginner-friendly and runs on AC or DC with easy arc starts. E6010 (DC+ only) is the pipe welder's go-to for deep-penetrating root passes. E7018 is the standard for structural welds requiring high strength and low hydrogen — it must be stored in a heated rod oven or used immediately from a sealed container to prevent moisture pickup, which causes hydrogen-induced cracking. Browse our full electrode and filler metal selection.
Yes — outdoor performance is one of stick welding's defining advantages. Because shielding comes from the electrode's flux coating rather than an external gas supply, wind cannot disrupt the shielding protection. This is why SMAW remains the standard for outdoor pipeline welding, structural erection, and field repairs across heavy industry. Standard precautions still apply: avoid welding on wet metal, position yourself so fumes travel away from your breathing zone, and observe AWS D1.1 preheat requirements for applicable base metals and temperatures.
DC (direct current) provides a smoother, more stable arc and is preferred for most professional structural and pipe welding. DC+ (electrode positive/DCEP) gives deeper penetration and is standard for E6010 and E7018. DC- (electrode negative/DCEN) deposits metal faster with less penetration. AC is used with electrodes that require it and is also valuable when welding magnetized steel to counteract arc blow. Most modern inverter welders offer both AC and DC output.
Yes — for structural, pressure vessel, and pipeline applications, welders must be qualified to the applicable standard (AWS D1.1, ASME Section IX, or API 1104). Qualification involves passing a standardized test weld evaluated by a Certified Welding Inspector (CWI). Midland Tool Supply offers on-site weld testing services to help contractors and facilities qualify welders to applicable codes. Contact us to learn more about our testing capabilities.
Shop Stick Welding Equipment at Midland Tool
Midland Tool has supplied Michigan's industrial and construction professionals with welding equipment since 1962. We stock stick welders and multi-process machines from Lincoln Electric, ESAB, and Miller — the brands trusted on the most demanding structural and pipe welding jobs. Browse our full selection of welding electrodes and filler metals, and find everything you need in our welding safety equipment section. Need help selecting the right machine or electrodes for your application? Our team has the expertise to match you with the right equipment. Ask about our StockUp program for volume electrode orders and consumable replenishment.
