Shielded metal arc welding
SMAW/stick welding: electrode and power-source selection, coating-specific handling, manual control, slag removal and qualified joint acceptance.
Tags: processes, welding, arc-welding
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An example task takes 12 minutes arc-on, eight electrode changes at 15 seconds each and five cleaning or inspection intervals at 40 seconds each. These separate activities total 17 minutes 20 seconds, with 69.2% arc-on. Add fit-up, handling, cooling waits and repairs if the estimate covers delivered-part throughput.
SMAW, also called MMA or stick welding, uses a flux-coated consumable electrode. Include slag removal, electrode replacement and cleaning between passes in the route. TWI: manual metal arc process
The coating supplies shielding, so a separate shielding-gas cylinder is not normally part of the basic setup. This does not make surface condition, technique or environmental protection irrelevant. Specify the actual material, joint and electrode rather than treating “stick welded” as a complete manufacturing instruction.
Select the electrode for the complete requirement
TWI distinguishes cellulosic, rutile and basic coatings, whose chemistry affects arc behavior, penetration, deposition and positional capability. Iron-powder additions can further change deposition behavior. These families are useful distinctions but do not replace a named electrode classification and product instruction. TWI: electrode/coating families
Miller lists base-metal properties, strength, current type, thickness/fit-up, position, service specifications and environmental conditions as selection inputs. A convenient diameter or familiar trade name is not enough. Miller: selecting stick electrodes
| Input | What to resolve |
|---|---|
| Base grades and incoming condition | Weldability, filler compatibility and thermal requirements |
| Joint geometry and access | Preparation, root technique, electrode access and pass sequence |
| Position and progression | Electrode suitability and approved technique |
| Required properties and environment | Strength, toughness, corrosion and hydrogen requirements |
| Power source and site arrangement | Permitted current/polarity, capacity and electrical setup |
Classification results are not component allowables. Specify the applicable consumable-standard edition, any supplementary designators and required certification, then qualify the joint in its delivered condition.
Named product example: preserve the qualifiers
Lincoln's Excalibur 7018 MR, publication C2.10.10, Issue Date 10/26, identifies AWS E7018 H4R and positions all except vertical down. For the 3.2 mm electrode, its typical operating table gives 90–160 A on DC+ and 100–160 A on AC, with DC+ listed first as preferred. These are named-product starting ranges, not a qualified setting for every joint or proof that another 7018 product behaves identically. Lincoln: Excalibur 7018 MR sheet
The sheet separately labels classification requirements and typical as-welded results, with an all-weld-metal footnote. It warns that actual weldment results vary with procedure, plate chemistry/temperature and design. Do not transfer its tensile or impact values unchanged to a diluted production joint. Lincoln: test-results disclaimer
Control storage without mixing electrode families
Lincoln's consumables catalog distinguishes low-hydrogen storage/re-drying from cellulosic and other non-low-hydrogen products. Its listed E6010/E6011 and related cellulosic group is specifically marked as not recommended for rebaking. It also explains that moisture pickup can increase diffusible hydrogen in low-hydrogen deposits and that excessive re-drying can damage coatings. An “R” moisture-resistance designation does not remove the need for proper handling. Lincoln C1.10, storage and handling, printed M-11–M-12
Use the actual manufacturer's label and applicable fabrication procedure for sealed storage, issue/exposure, holding, permitted reconditioning and discard. Keep holding temperature separate from re-drying temperature. Record container opening and exposure where the approved system requires it; do not invent one oven schedule for every coating, brand and strength level.
Haynes supplies different guidance for its own nickel/cobalt-alloy coated electrodes, including sealed storage and specific oven/reconditioning practices. That recommendation belongs to its product family and should not be applied to cellulosic steel electrodes. Haynes: SMAW electrode handling
Equipment and manual process control
TWI describes a constant-current, drooping-characteristic power source for MMA. Confirm the selected electrode's AC/DC and polarity requirements, the machine's operating capability and the approved lead/return arrangement. A maximum-current rating alone does not establish performance with the required electrode or duty. TWI: equipment for MMA
The welder controls arc length, travel, angle and placement as the electrode is consumed. Current, electrode diameter and joint preparation must work together. Establish root, fill/cap and restart techniques, interpass cleaning, temperature control and any postweld treatment in the procedure. Arc-start aids or force controls are equipment features, not substitutes for qualification.
Haynes' alloy-specific guidance stresses short arc length and generally favors stringer beads, while allowing manipulation where needed. Its technique and polarity recommendations must remain scoped to the described coated-alloy products, not every SMAW application. Haynes: operating technique
Original production-time example
Use the stated arc, electrode-change and interpass times as separate, non-overlapping activities:
- Electrode changes: 8 × 15 = 120 seconds.
- Cleaning/inspection: 5 × 40 = 200 seconds.
- Modeled total: 720 + 120 + 200 = 1,040 seconds, or 17 minutes 20 seconds.
- Arc-on fraction of that modeled time: 720 / 1,040 = 69.2%.
The model is 30.8% non-arc before setup, fit-up, handling, cooling waits or repairs. Verify actual utilization and delivered-part throughput separately.
Qualification and release
For steel fusion welding, ISO 9606-1:2012, edition 2, July 2012, addresses welder qualification with emphasis on manual electrode/torch manipulation. ISO lists confirmation in 2023 and corrigenda 1:2012 and 2:2013; its proposed successor remains a draft at review. Welder qualification is distinct from qualification of the welding procedure and acceptance of an individual production weld. ISO 9606-1:2012
Determine the governing application code, approved procedure and personnel requirements. Specify final weld geometry, permitted imperfections, examination method/extent, sampling and repair rules. Separate surface appearance from fusion, slag inclusions, cracking, dimensions and required mechanical/service performance. Slag that lifts easily or a smooth cap does not prove subsurface conformance.
Provide the controlled drawing, base/electrode traceability, coating-handling plan, approved preparation and thermal sequence, equipment/polarity, pass/restart requirements and final acceptance criteria. Evaluate changes in electrode product, material condition or process sequence against the qualified route.
Source versions
Reviewed 2026-11-01. The retrieved Excalibur PDF explicitly prints C2.10.10, Issue Date 10/26; the storage catalog's actual back cover prints C1.10, Issue Date 10/23. Search publication estimates are not used as document dates. ISO's edition/corrigenda are identified above. No separate technical issue date was verified for the cited live TWI, Miller or Haynes guidance. The time example and handoff recommendations are original.