Creating Good Quality Stick Welds…
Stick welding is the most familiar form of arc welding, but creating a good weld may not be easy for a beginner. Unlike MIG welding where you principally ‘point and shoot’ stick welding has a higher skill level and requires mastery of certain techniques.
Tips...
If you are welding with low-alloy steels and carbon steels, they will have a tendency to crack, particularly when welding on heavy plate and rigid structures. Because of this, you should use special precautions. In addition, steels with high sulphur and phosphorus contents are not recommended for production welding. If they must be welded, use small diameter, low hydrogen electrodes. Welding with a slow travel speed will further keep the molten pool, allowing gas bubbles time to boil out, creating a better-finished weld.
Choose a Joint Position and Electrode that is favourable to the Metal, Joint position can have a great affect on finished weld quality. When welding on 10 to 18 gauge sheet steel, the fastest travel speeds are obtained with the work positioned at a 45 to 75 degrees downhill angle. Also, don’t over weld or make a weld that is larger than needed for joint strength - this may lead to burn through.
For welding mild steel plate with a thickness greater than or equal to 5mm, it is best to have the work positioned flat, because it creates an easier electrode manipulation for the operator. Lastly, high carbon and low-alloy steel plate can best be welded with the work in the level position.
Joint dimensions are chosen for fast welding speeds and good weld quality. Clamping set-up must be consistent for the entire joint. Since sheet metal and most fillet and lap joints are tightly clamped through their entire length, gaps or bevels must be controlled over the entire joint. Any deviation in a given joint will force the operator to slow the welding speed to avoid burn through and manipulate the electrode to adjust for the setup variation.
Spatter...
Although spatter does not actually affect the weld properties, it does incidentally create a poor appearance and increases cleaning costs. There are a number of ways to control spatter. A lower current and shorter arc length are often great for reducing spatter, a change of the electrode angle. Finally, look for arc blow conditions and be sure the electrode isn’t wet.
Undercutting...
Undercutting often only affects the welds appearance, but it can actually impair weld strength when the weld is loaded in stress or fatigue applies. To prevent undercut, reduce the current and slow the travel speed, or simply reduce size until you have a puddle size you can handle. Then change the electrode angle so the arc force holds the metal in the corners. Use a constant travel speed and avoid excessive weaving.
Shallow Penetration...
For effective strong welds, penetration to the bottom of the joint is required. To overcome shallow penetration, try higher currents or slower travel. Use small electrodes to get into deep fine grooves.