🔧 SMAW (Stick Welding) Beginner’s Guide
📌 What is SMAW?
SMAW stands for Shielded Metal Arc Welding, also known as stick welding. It uses a flux-coated electrode to create an arc between the rod and the base metal. The flux melts and forms a gas shield and slag to protect the weld pool.
🧰 1. Basic Equipment You Need
| Tool / Equipment | Description |
|---|---|
| Welding Machine (AC/DC) | Converts power to generate an arc. |
| Electrodes (e.g., E6011, E6013, E7018) | Stick rods that melt and deposit weld metal. |
| Electrode Holder | Holds and conducts current to the electrode. |
| Ground Clamp | Completes the electrical circuit. |
| Welding Helmet | Auto-darkening lens to protect eyes. |
| Welding Gloves & Jacket | Protects hands and body from sparks. |
| Chipping Hammer & Wire Brush | Removes slag after welding. |
| Angle Grinder (Optional) | For preparing and cleaning metal. |
📗 2. Safety First
⚠️ SMAW produces:
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UV radiation – always wear a helmet and long sleeves.
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Sparks and spatter – wear gloves, leather jacket, and boots.
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Fumes – work in a well-ventilated area.
Safety Checklist:
✅ Always wear PPE
✅ Never weld near flammable materials
✅ Use welding curtains or screens
✅ Keep a fire extinguisher nearby
🧪 3. Understanding the Electrode
Electrodes have codes, for example: E6013
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E = Electrode
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60 = 60,000 psi tensile strength
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1 = Can be used in all positions
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3 = Type of flux coating and polarity
✅ Beginners often start with E6013 because it's forgiving and easier to control.
⚡ 4. Welding Machine Settings
Start with these settings for 2.5mm (3/32") E6013 electrodes:
| Metal Thickness | Amperage (approx) |
|---|---|
| 1.5 – 2.0 mm | 40–60 A |
| 3.0 mm | 90–110 A |
| 5.0 mm | 120–140 A |
✅ Always strike like you're lighting a match
✅ Maintain a short arc (~2–3 mm gap from base metal)
🔥 5. Welding Techniques
A. Striking the Arc
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Scratch the electrode like a match OR tap and lift quickly
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Listen for a steady buzzing sound
B. Travel Angle
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Use a drag or backhand technique
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Hold rod at 15°–30° tilt from vertical, pointed in direction of travel
C. Travel Speed
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Too slow = wide, high bead with too much heat
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Too fast = narrow bead, poor fusion
🎯 Goal: Smooth, consistent bead with uniform ripples
🧱 6. Basic Weld Types to Practice
| Weld Type | Description |
|---|---|
| Bead on plate | Practice on flat steel without joints |
| Fillet weld | Welds in corners (T-joints) |
| Lap joint | One piece overlaps another |
| Butt joint | Two plates edge to edge |
🛠️ 7. Common Beginner Mistakes
| Mistake | Fix |
|---|---|
| Arc too long | Keep a short arc (~2–3 mm) |
| Electrode sticking | Increase amperage or strike quicker |
| Poor penetration | Use correct amperage & clean metal |
| Uneven bead | Maintain steady hand and angle |
📈 8. Practice Routine for First Week
| Day | Practice |
|---|---|
| 1 | Safety & setup, striking arc, short beads |
| 2 | Bead on plate with 6013, varying amps |
| 3 | Fillet welds (T-joint) |
| 4 | Lap joints |
| 5 | Vertical position welding |
| 6 | Overhead try-outs (advanced) |
| 7 | Clean-up, inspection, and re-do weak welds |
🔍 9. Tips for Progress
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Always clean your metal before welding (remove rust, paint, oil).
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Keep your hand steady by resting your wrist or elbow.
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Watch the molten pool, not the arc.
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Learn to read the weld: color, ripples, slag coverage.
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