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Welding
Stick welding, also known as Manual Metal Arc (MMA) or Shielded Metal Arc (SMAW) welding, is one of the oldest and simplest welding techniques in use today. It is favoured by many for its ease of setup and relatively straightforward learning curve, making it an excellent choice for beginners. In this article, we explore the basics of stick welding and specifically focus on the importance of polarity in this welding process.
Manual Metal Arc (MMA) welding, or stick welding, is an arc welding process that involves creating an arc between a flux-covered electrode and the base metal. This arc melts the electrode and the base metal, creating a pool of molten metal that is a mixture of the consumable electrode and the base metal and this forms a weld. The coating of flux on the electrode is vaporised and creates a gas shroud around the molten weld pool that keeps out air and prevents oxidation.
Stick welding is straightforward and requires minimal equipment. To initiate an arc, you need a complete electrical circuit. Here is a breakdown of how stick welding works:
Various types of electrodes are available for stick welding, each with its own classification code indicating its properties. For mild steel electrodes, the code starts with 'E,' followed by a 4-digit number (e.g., E6013).
Here's what each part of the electrode code represents:
For beginners learning stick welding, E6013 electrodes are a popular choice. They are considered general-purpose, work well in various applications, can be used in all positions, and are easy to strike.
The size of the electrode you select depends on the thickness of the metal that is being welded. As a general guideline, a 2.5mm diameter electrode suits metal with a thickness of 3mm to 6mm, a 3.2mm electrode is suitable for 6mm to 12mm, and a 4mm electrode works for metal between 12mm and 25mm. Lots of data is available from the manufacturers of the consumables on grade selection, electrode diameter and suggested parameters.
Stick welding can be performed in both AC (Alternating Current) and DC (Direct Current). For most stick electrodes, the default polarity is Direct Current Electrode Positive (DCEP), meaning the current flows positively from the negative to the positive. In this setup, the current flows from the base plate into the electrode. Despite the counterintuitive direction, the heated electrode melts back into the base material, providing strong penetration, (the depth that the heat from the arc melts the base material). Consequently, DCEP is suitable for thicker section joints.
Some electrodes can also be used with Direct Current Electrode Negative (DCEN), where the current flows from the electrode into the plate. This method gives less penetration and gives the welder more control over it.
Some electrodes are developed for AC polarity welding, the penetration falls between DCEN and DCEP, as the current alternates between positive and negative polarities during welding. AC polarity can be used where there is a strong potential for ‘arc blow’, this is arc deflection caused by distortion of the magnetic field due to the welding current. AC polarity is also more forgiving with contaminated surfaces as it has an inherent cleaning action.
It should be noted that each pack of electrodes will state which polarity is to be used with them, the electrodes will only weld successfully when these recommendations are followed.
Stick welding is a versatile welding method and can be used on a huge range of materials, typically:
Stick welding offers several advantages that make it a preferred choice for many:
While stick welding has many advantages, it also has some limitations:
In conclusion, stick welding is an accessible and cost-effective way to start welding, it can be applied to a huge variety of materials in almost all material thicknesses and in every welding position. Polarity is one of several factors that need to be understood when selecting the correct electrodes for any specific application to achieve welds with the required strength and appearance. The variety of flux coatings, their influence on the metallurgy of the weld and their effect on weldability is another subject worth investigating.
For further insights into welding, make sure to explore the following articles on ESAB University.