Stick (SMAW)

Stick (SMAW) joins metals using a flux-coated consumable electrode and arc heat, valued for portability, low equipment cost, and outdoor robustness.

Overview

Stick welding (SMAW) is a manual arc welding process that melts a flux-coated electrode to create a weld deposit and shielding gas/slag. It’s widely used on carbon steel and low-alloy steel, and works well on thicker sections, rusty or painted surfaces (within reason), and in wind where gas-shielded processes struggle.

Choose SMAW for field repairs, structural fabrication, and low-to-medium volume work where access is limited, power is simple, and setup must be fast. Tradeoffs: slower deposition than wire-fed processes, frequent stops for rod changes, more spatter and slag cleanup, and higher dependence on welder skill. Thin material is easy to burn through, and cosmetic/low-spatter requirements often push you toward other processes. Qualification (WPS/PQR) and consumable control matter when code compliance is required.

Common Materials

  • Carbon steel (A36)
  • Steel 1018
  • 4140 steel
  • Stainless steel 304
  • Cast iron

Tolerances

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Applications

  • Structural steel connections and brackets
  • Heavy equipment repair welds
  • Pipeline and pipe supports
  • Farm/industrial equipment fabrication
  • Weld buildup and hardfacing
  • Maintenance welding in the field

When to Choose Stick (SMAW)

SMAW fits low-to-medium volume welding where portability and simple equipment matter more than speed or appearance. It’s a strong choice for thicker steel parts, outdoor work, and repair situations with less-than-ideal surface condition. Plan for post-weld slag removal and variability driven by operator technique.

vs MIG (GMAW)

Choose SMAW when you need outdoor welding, long leads, and minimal shielding-gas logistics. It tolerates wind and less-controlled jobsite conditions better, and equipment is typically simpler to deploy for repairs and small runs.

vs TIG (GTAW)

Choose SMAW when throughput and robustness matter more than precision aesthetics. It’s generally better suited to thicker sections, dirty/oxidized steel, and field repair work where GTAW’s cleanliness and gas shielding are hard to maintain.

vs Resistance Welding

Choose SMAW when parts can’t be fixtured between electrodes or the joint isn’t a lap seam suited to spot/projection welding. SMAW handles large structures, varied joint types, and low-volume work without dedicated tooling or high electrical infrastructure.

vs Laser Welding

Choose SMAW when fit-up is inconsistent, access is limited, or the environment is not production-controlled. SMAW is more forgiving on gaps and surface condition and is practical for one-off fabrication and repair where laser capital and fixturing aren’t justified.

vs Brazing & Soldering

Choose SMAW when you need a true fusion weld with higher strength and temperature capability on ferrous structures. SMAW is typically preferred for load-bearing steel joints where filler-metal bonding (without melting the base) isn’t acceptable.

Design Considerations

  • Call out the weld symbol, size (leg/throat), length, and intermittent vs continuous welds on the drawing
  • Provide realistic joint access for the electrode holder and chipping/cleanup tools, especially in corners and inside frames
  • Avoid very thin sections at the weld zone or specify backing/edge prep to reduce burn-through risk
  • Specify base metal grade and thickness clearly so the shop can select electrode classification (e.g., E6010/E7018) and WPS
  • Define acceptable spatter/appearance and whether grinding/flush finishing is required—this often dominates labor cost
  • If code compliance matters, state the governing code/standard and inspection requirements (VT, MT, UT) up front