Mastering Stick Welding for Different Metal Thickness

TIG welding stainless steel can be a rewarding experience when approached with the right techniques. In this comprehensive guide, we will walk you through the challenges posed by stainless steel and the different types of stainless steel. As well as the step-by-step process of setting up and executing high-quality TIG welds on this versatile material.

Stick Welding Different Thickness Metals

Stick welding is a straightforward process that doesn’t require too much skill or special equipment. For example TIG welding processes. It can also be used to weld on the field in windy conditions. Stick electrodes have a layer of flux that protects the weld puddle from contamination. In addition, it can burn through rust, paint, and dirty metals.

With added high deposition rates and low costs, it is not a surprise why Stick welding is a go-to method when project or repair work needs to be done quickly and cheaply. However, appearance-wise, stick welding cannot match significant TIG welds. 

Regarding the different thickness metals, Stick welding does exceptionally well with medium-thickness and thick metal. But it is less commonly used to weld thin metal. No features could limit the heat output like in MIG welding or TIG welding processes, but higher penetration handles thick metal very well.

Let’s see what you need and how to weld different metal thicknesses using Stick welding.

Stick Welding Thin Metal:

Welding metal thinner than 1/8″ presents challenges due to the inherent heat output of stick welding. To tackle this, selecting the right equipment is crucial. A welder with a low amp start feature is ideal for thin mild steel. Choosing the correct stick welding rod, such as E6011 or E6013, and employing DCEN polarity for lower penetration is essential. Weld preparation, proper cleaning, and the use of techniques like skip welding help minimise distortion.

Weld Preparation And Welding Method Required To Weld Sheet Metal

While SMAW is known for excellent results when welding through dirt or rust, you want to clean surfaces when dealing with thin metals, especially when working with E6013 electrodes. Also, leaving a large gap is not recommended, as pieces will distort, so a nice fit-up is required.

Since it is challenging to control heat input with SMAW, you will need extra attention with thinner material. That explicitly applies when using longer welds. Using the skip welding technique with a number of intermittent or stitch welds can help minimise distortion and evenly distribute the heat.

Stick Welding Medium-Thickness Metal:

Stick welding excels in welding medium-thickness mild steel. Typically plates up to 1/4″ or 1/2″. A 160 amp stick welder equipped with features like Arc force and hot start, is suitable for these applications. Stick welding medium-thickness metal is certainly more forgiving than welding sheet metal, but you will still need some time to master the technique for the best results.

Without further ado, let’s see what to do with medium-thickness weld metal.

Filler Metal (Electrode) Selection

As the thickness of the base metal increases, you will need to use a larger diameter Stick electrode. The correct stick welding rod size is the largest one that fits in the joint, ensuring proper penetration and fusion, the most common being 1/16, 5/64, and 3/32. Like with TIG welding, you want one step thinner electrode than the base metal. For example, 1/8″ metal will require a 3/32″ rod.

You have more room to select the electrode type than sheet metal welding, with commonly used 6010, 6011, 6013, and 7018. The best part is that the properties of the electrode can match your projects perfectly. For example, if you need more heat, you can use E6010. While E6011 provides a soft arc, minimal spatter, moderate penetration, and easily removable slag.

As a beginner, consider starting with rutile rods such as E6013 and E7014. They provide significantly more forgiving results than cellulosic rods, such as E6011, or low-hydrogen rods, such as E7018. However, rutile rods offer lower-quality results. But, you can use them to work your way up to mastering more challenging electrodes.

You should pay attention to the electrode polarity when making a selection. For example, particular electrodes, such as E6010, are designed for DCEP only, while its alternative, E6011, can work with both AC and DC current. In addition, keep in mind that inverter-based Stick welders can have issues with 6010s, causing inconsistent results with a highly unstable arc.

Welder Settings For Medium Thickness Metal

The current and polarity should be the first thing you should consider when setting your welder for medium-thickness steel. Current and polarity settings will vary on the selected electrode and overall project requirements.

For example, DCEP (DC+) current runs 10-15% hotter compared to DCEN (DC-) and AC. Therefore, welding medium-thickness metal will, in most cases, require DCEP polarity. DCEN, as we said, is more useful in thin metal welding, while AC is commonly helpful when an arc blow occurs.

Arc blow is a specific welding issue that you might notice if the arc wanders off from the weld puddle due to the magnetics or thermal properties of the base metal. So if you feel like you cannot control it, you should switch to AC current, of course, if your stick welder and electrode allow it. However, welding with AC offers relatively low penetration, and alternating from the positive to the negative side can cause the arc to extinguish.

Next, you will need to select the correct amperage. The amperage is usually stated on the box or enclosed materials of the electrode package. In addition, you can use a rule of thumb that says 1 amp for each .001-inch electrode diameter.

Low amperage will cause the electrode to stick excessively to the piece, eventually resulting in arc stuttering. Conversely, high amperage makes the weld pool extremely fluid and almost uncontrollable, with high arc sounds. While it is less likely to burn through medium-thickness metal, you should still pay attention.

Weld Preparation And Welding Technique

Stick/Arc welding thicker metal certainly allows more weld preparation and design options, as pieces can be placed in horizontal, vertical, or overhead positions, with T-joint, butt weld, corner joint, and many more. Even though SMAW is much more tolerant of dirt, oil, or rust, cleaning the pieces is always a good practice.

Regarding the welding technique for medium-thick metal, there are certain guidelines but no specific rules. Therefore, SMAW allows welders to develop their own style and electrode manipulation as long as they follow specific steps.

Stick electrodes can be run using a stringer or straight bead, or weaving technique. Metals up to 1/4″ usually don’t have a large gap, so it is not necessary to weave with medium-thickness metal. Instead, you should pay attention to arc length, travel angle, and travel speed.

The arc length represents the distance between the electrode and the puddle. As a rule of thumb, it should not exceed the diameter of the core of the electrode. If you keep the electrode too close, it will stick and extinguish. Meanwhile, lifting it way up high will cause spatter, porosity, or undercut.

The travel angle is similar to other welding techniques, and it includes holding the electrode at 5-15 degrees and dragging (backhand) technique in horizontal and flat positions. Vertical up welding requires a push technique at 0 to 15 degrees.

Travel speed should be adjusted to the thickness of the metal. Low travel speed creates wider weld beads with shallow penetration. The electrode isn’t fusing the two pieces; it just sits on top of the base metal. Meanwhile, fast travel speed creates narrow weld beads, again, with penetration problems and fear of undercut or underfill.

As a beginner, it might take time to master proper electrode manipulation, travel speed, and arc length, which is a reason SMAW is a bit more complex than MIG welding but still not as hard as TIG welding. However, once you master the technique, you will enjoy the versatility of successfully and quickly welding medium-thickness steel without shielding gas.

Stick Welding Thick Metal:

Stick welding proves effective for joining thicker metals found in applications like farm and ranch work, plant maintenance, and shipbuilding. Beveling the pieces and using multiple passes is common for welding 3/16″ inch metal and larger. The choice of electrodes, such as E-XX10 for root passes and E-7018 for fill and cap passes, plays a crucial role. Proper weld preparation, including beveling and aligning, is essential for success in stick welding thicker metals.

Electrode Choice

Stick welding thick plates will require a manageable size of electrodes since you are bringing the root at a reasonable thickness. As a result, you will need a 1/8-inch or 5/8-inch rod for the first, initial, or root pass and a 5/32 or a 3/16-inch rod for filler and cap passes.

To weld the root pass, an all-position cellulose E-XX10 welding electrode is used (6010, 7010, 8010). The standard travel speed is 12 inches per minute, with reverse (DC+) polarity. This approach creates a strong foundation for the upcoming welds with slag that easily falls off. If, in any case, an arc blow occurs, you can switch to its smaller-brother 6011s, which works with AC current, but offer somewhat weaker results.

Upcoming fill and cap passes are usually done with E-7018 low-hydrogen electrodes. This is because 7018s produce strong, ductile welds that fill the opening nicely, making them the backbone of structural welding.

Weld Preparation For Thicker Pieces

Weld preparation for thicker piece welding is nearly as important as welding itself. For plates up to 3/16″ thick, you should use a V-bevel to prepare the pieces. 1/2″ to 3/4″ pieces will require a U-bevel, which can take more filler metal to ensure stronger welds. Finally, pieces thicker than 3/4 inch will need a double V or U-bevel joint configuration.

The gap should be even along the entire piece of plate or pipe, and aligning the parts is crucial. Of course, cleanliness should be disregarded. Once aligned, you can use tack welds to keep everything in place, so you can start welding.

Multi-pass Stick Welding Technique

Compared to medium-thickness plates, thicker pieces now have a larger gap between them. So you will have to use a weaving manipulation with a pushing technique for 3/16″-1/2″ V bevels or a pull technique for U bevels larger than 1/2″ to fill it correctly and get the solid weld bead. The weaving procedure requires more time and practice to perform. However, you can practise by clamping a pen in your electrode holder and drawing on a piece of paper.

Even though the 6010s produce a slag that easily falls off, cleaning it thoroughly before performing any other passes is crucial. Any leftover slag can cause slag inclusions that can interfere with the integrity of the weld, and they are hardly noticed without x-ray or ultrasonic testing.

After a root pass, you can opt to put a hot pass, performed within 5 minutes after completing the initial weld. The hot pass is used to correct some imperfections noticed in the root pass, taking 5-10% more heat to penetrate the first pass.

Laying a foundation is a crucial part of making the strongest stick weld on the thick metal, and afterward, you will need to fill the gap. The filler pass is done with smaller diameter E7018 rods, but you can use any convenient electrode manipulation method.

Highly skilled welders usually use weaving techniques for cap weld to produce high-aesthetic TIG-like welds. However, you will be more than fine with a simple finish with 7018s.

Finally, it will take some time to get the hang of the multi-pass Stick welding procedure. But once you master it, you unlock the ability to weld metal regardless of its thickness.

Final Thoughts:

Stick welding offers a versatile and cost-effective solution for welding different thickness metals. With the right equipment, electrode selection, and welding techniques, welders can achieve quality results across a range of applications. Whether working with thin, medium, or thick metals, mastering stick welding opens up possibilities for various projects, making it a valuable skill for both professionals and hobbyists alike.

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