Stick Welding - How To Create High Quality Welds

Stick Welding - How To Create High
Quality Welds
Stick Welding
Stick welding is the most common form of arc welding, but creating a good weld may not be
easy for the beginner. Unlike wire welding where you basically "point and shoot," stick
welding has a higher skill level and requires mastery of certain techniques.
This article will offer tips that you can follow to increase your chances of creating a high
quality stick weld - right from the start. It will also discuss how to troubleshoot problems and
correct them.
1. Select Steel in the Normal Range

Whenever possible, select steel within the "normal range," these include AISI-SAE 1015 to
1025 steels with 0.1 percent maximum silicon and sulfur content under .035 percent.
Selecting these steels will make the stick welding process easier since they can be welded at
fast speeds with minimum cracking tendencies.
If you are welding with low-alloy steels and carbon steels with chemistry compositions above
the "normal range", they will have a tendency to crack, particularly when welding on heavy
plate and rigid structures. Because of this, you should use special precautions. In addition,
steels with high sulphur and phosphorus contents are not recommended for production
welding. If they must be welded, use small diameter, low hydrogen electrodes. Welding with
a slow travel speed will further keep the puddle molten allowing gas bubbles time to boil out,
creating a better-finished weld.
2. Choose a Joint Position and Electrode that is Conducive to the Metal

Joint position can have a great affect on finished weld quality. When welding on 10 to 18
gauge sheet steel, the fastest travel speeds are obtained with the work positioned at a 45 to 75
degrees downhill angle. Also, don't overweld or make a weld that is larger than needed for
joint strength - this may lead to burnthrough.
For welding mild steel plate with a thickness greater than or equal to 3/16", it is best to have
the work positioned flat, because this will make operator manipulation of the electrode the
easiest. Lastly, high carbon and low-alloy steel plate can best be welded with the work in the
level position.

3. Follow Simple Principles for Joint Geometry and Fitup
Joint dimensions are chosen for fast welding speeds and good weld quality. Proper joint
geometry is based upon some simple principles:
1. Fitup must be consistent for the entire joint. Since sheet metal and most fillet and lap
joints are tightly clamped for their entire length, gaps or bevels must accurately be
controlled over the entire joint. Any variations in a given joint will force the operator
to slow his or her welding speed to avoid burnthrough and manipulate the electrode to
adjust for the fitup variation.
2. Sufficient bevel is required for good bead shape and penetration; insufficient bevel
prevents the electrode from getting into the joint. For example, a deep, narrow bead
may lack penetration and has a strong tendency to crack.
3. Sufficient root opening is needed for full penetration, while excessive root opening
wastes weld metal and slows welding speed. It is important to note that the root
opening must be consistent with the diameter of the electrode being used.
4. A root face or a backup strip is required for fast welding and good quality. Feather
edge preparations require a slow costly seal bead. However, double V butt joints
without a land are practical when the seal bead cost is offset by easier edge
preparation and the root opening can be limited to approximately 3/32".
5. In general, weld seal beads on flat work with 3/16" AWS E6010 at approximately 150
amps DC+. Use 1/8" at approximately 90 amps DC+ for vertical, overhead, and
horizontal butt welds. For low hydrogen and seal beads, weld with an AWS EXX18
electrode at approximately 170 amps.
4. Avoid Buildup and Overwelding

Fillets should have equal legs and a nearly flat bead surface. Buildup rarely should exceed
1/16". Extra buildup is costly in material and time, adds little to weld strength and increases
distortion. For example, doubling the size of a fillet requires four times as much weld metal.
Also, it costs 2/3 more to butt weld a single-V with 1/8" land and 1/32" root opening when
the excess buildup approaches 1/8".
5. Clean the Joint Before Welding

To avoid porosity and attain the ideal weld travel speeds, it is important to remove excessive
scale, rust, moisture, paint, oil and grease from the surface of joints. If such elements cannot
be removed, use AWS E6010 (Fleetweld® 5P+) or AWS E6011 (Fleetweld® 35 or
Fleetweld® 180) electrodes to penetrate through the contaminants and deeply into the base
metal. Slow the travel speed to allow time for gas bubbles to boil out of the molten weld
before it freezes.
6. Choose the Right Electrode Size

Large electrodes weld at high currents for high deposit rates. Therefore, use the largest
electrode practical to be consistent with good weld quality. But, electrode size may be limited
especially on sheet metal and root passes, where burnthrough can occur. As a general rule,
3/16" is the maximum electrode size practical for vertical and overhead welding, while 5/32"
is the maximum size practical for low hydrogen. In addition, joint dimensions sometimes
limit the electrode diameter that will fit into the joint.
Troubleshooting Weld Defects
Here are some of the most common stick welding problems and how to correct them:
Spatter
Although spatter does not affect weld strength, it does create a poor appearance and increases
cleaning costs. There are several ways to control excessive spatter. First, try lowering the
current. Make sure it is within the range for the type and size electrode you are welding with
and that the polarity is correct. Another way to control spatter is to try a shorter arc length. If
the molten metal is running in front of the arc, change the electrode angle. Finally, look for
arc blow conditions (commonly referred to as a wandering arc), and be sure the electrode is
not wet.
Undercutting
Undercutting is frequently just an appearance problem, but it can impair weld strength when
the weld is loaded in tension or subjected to fatigue. To eliminate undercut, reduce current
and slow travel speed, or simply reduce size until you have a puddle size you can handle.
Then change the electrode angle so the arc force holds the metal in the corners. Use a uniform
travel speed and avoid excessive weaving.
Wet electrodes
If polarity and current are within the electrode manufacturer's recommendations but the arc
action is rough and erratic, the electrodes may be wet. Try dry electrodes from a fresh
container. If the problem recurs frequently, store open containers of electrodes in a heated
cabinet.
Wandering arc
With DC welding, stray magnetic fields cause the arc to wander from its aimed course. This
is a greater problem at high currents and in complex joints. To control a wandering arc, the
best option is to change to AC welding. If that doesn't work, try using lower currents and
smaller electrodes or reduce the arc length. In addition, you can change the electrical path by
shifting the work connection to the other end of the piece or by making connections in several
locations. You may also do this by welding toward heavy tacks or finished welds, using run-
out tabs; adding steel blocks to change work current path or tacking small plates across the
seam at the weld ends.
Porosity
Most porosity is not visible. However, since severe porosity can weaken the weld, you should
know when it tends to occur and how to combat it. Begin by removing scale, rust, paint,
moisture and dirt from the joint. Be sure to keep the puddle molten for a longer time to allow
gases to boil out before it freezes. If the steel has a low carbon or manganese content, or a
high sulfur (free machining steel) or phosphorus content, it should be welded with a low-
hydrogen electrode. Sometimes the sulfur content of free machining steels can be high
enough to prevent successful welding. Minimize admixture of base metal into weld metal by
using low current and fast travel speeds for less penetration. Or, try using a shorter arc length.
A light drag technique is recommended for low hydrogen electrodes. For surface holes, use
the same solutions that are used for porosity. If you are using AWS E6010 or 11 electrodes,
make sure that they are not too dry.
Poor Fusion
Proper fusion means the weld must physically bond strongly to both walls of the joint and
form a solid bead across the joint. Lack of fusion is often visible and must be eliminated for a
sound weld. To correct poor fusion, try a higher current and a stringer bead technique. Be
sure the edges of the joint are clean, or use an AWS E6010 or 11 electrode to dig through the
dirt. If the gap is excessive, provide better fitup or use a weave technique to fill the gap.
Shallow Penetration
Penetration refers to the depth the weld enters into the base metal, and usually is not visible.
For full- strength welds, penetration to the bottom of the joint is required. To overcome
shallow penetration, try higher currents or slower travel. Use small electrodes to reach down
into deep narrow grooves. Remember to allow some gap at the bottom of the joint.
Cracking
Cracking is a complex subject because there are many different types of cracks that occur in
different locations throughout a weld. All cracks are potentially serious, as they can lead to
complete failure of the weld. Most cracking is attributed to high carbon or alloy content, or
high sulfur content in the base metal.
To control this cracking, try these tips:

1. Weld with low hydrogen electrodes
2. Use high preheats for heavier plate and rigid joints
3. Reduce penetration by using low currents and small electrodes. This reduces the
amount of alloy added to the weld from melted base metal
4. Fill each crater before breaking the arc
5. On multiple pass or fillet welds, be sure the first bead is of sufficient size and of flat
or convex shape to resist cracking until the later beads can be added for support. To
increase bead size, use slower travel speed and a short arc technique or weld 5 degrees
uphill. Always continue welding while the plate is hot
6. Rigid parts are more prone to cracking. If possible, weld toward the unrestrained end.
Leave a 1/32" gap between plates for free shrinkage movement as the weld cools.
Peen each bead while it is still hot to relieve stresses
Conclusion
By following the tips offered here, even a beginner can create a high quality weld. And, if
you are experiencing problems, being able to troubleshoot and make corrections will also turn
a beginning stick welder into a professional in no time.

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Stick Welding - How To Create High

1. Select Steel in the Normal Range

2. Choose a Joint Position and Electrode that is Conducive to the Metal

4. Avoid Buildup and Overwelding

5. Clean the Joint Before Welding

6. Choose the Right Electrode Size

Troubleshooting Weld Defects

To control this cracking, try these tips:

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