Stick or MSAW welding

Advantage Fabricated Metals performs a number of welding processes. The two most
common welding processes we use include TIG, an acronym for Tungsten Inert Gas welding
and MIG, an acronym for Metal Inert Gas welding. TIG is also referred to as GTAW (Gas T
ungsten Arc Welding) and Heliarc®. MIG also is referred to as GMAW (Gas Metal Arc
Welding). We also provide stick or MSAW welding.

Shielded Metal Arc Welding (SMAW) is frequently referred to as "stick" or "covered

electrode" welding. Stick welding is among the most widely used welding processes.

The flux covering on the electrode melts during welding. This forms the gas and slag to
shield the arc and molten weld pool. The slag must be chipped off the weld bead after
welding. The flux also provides a method of adding scavengers, deoxidizers, and alloying
elements to the weld metal.

When an arc is struck between the metal rod (electrode) and the workpiece, both the rod and
workpiece surface melt to form a weld pool. Simultaneous melting of the flux coating on the
rod will form gas and slag which protects the weld pool from the surrounding atmosphere.
The slag will solidify and cool and must be chipped off the weld bead once the weld run is
complete (or before the next weld pass is deposited).

The process allows only short lengths of weld to be produced before a new electrode needs to
be inserted in the holder. Weld penetration is low and the quality of the weld deposit is highly
dependent on the skill of the welder.

Process characteristics of Shielded Metal Arc Welding

(SMAW/Stick)
SMAW welding:

 Uses a electrode rod that is quickly consumed,

 Uses equipment that is simple, inexpensive, and highly portable,
 Uses an electrode that provides and regulates its own flux,
 Provides all position flexibility,
 Is less sensitive to wind or drafts,
 Yields a weld with a variable quality and appearance based on operator skill,
During the SMAW welding process the arc is established, the flux coating on the rod
disintegrates and then forms a gas that shields the weld from the atmosphere. The slag that is
produced by the flux coating prevents the weld metal from oxidizing.

Equipment required to perform the SMAW welding process includes a constant current
power source that supplies the power to the consumable rod electrode.
The SMAW welding process typically is capable of producing three types of welded joints.
They are:

 Butt joint
 Lap joint,
 T-joint, and
 Fillet weld.

The illustration below shows these four common welded joints.

Flux-coated electrodes are available in many core wire diameters and lengths. Matching the
electrode properties to the base materials as a general rule for choosing the type of electrode.
Available electrodes types include aluminum bronze, bronze, mild steel, nickel, and stainless
steel.

Materials commonly welded using the SMAW process include mild steel, cast iron, and
stainless steel.