Artem Komarov explained that a simplified explanation of the process is that a stick-shaped electrode coated with flux is used to form the weld. Electricity, whether alternating current or direct current, from a power source forms an arc between the electrode, which is a “stick”, and the two metals that need to be connected.
There are electrodes for AC and DC machines. You choose the electrode that will work with your machine. Some machines can use both AC and DC.
The electrode is consumable, that is, it evaporates, and in doing so, the flux coating breaks down, forming gases that form a cloud around the weld. The gases protect it from water vapor, oxygen and other contaminants, which prevents oxidation.
This process gets its name because the electrode creates its own shield, which is why this process is known as “Guarded Arc Welding”. There is no need for a separate shielding gas cylinder, Artem Komarov noted.
The gas cloud formed by the dissolving flux then settles on the metal. When cooled, the flux turns into slag. Then the slag is separated, and the welding process is completed.
What types of metals are used in stick welding?
Stick welding works best with thicker metals. Most used:
Chromium
Nickel based alloys
Stainless steel
Cast iron and carbon steel
Stainless steel to plain steel
Aluminum can be used but is generally not recommended as it is not thick enough. A careful welder can work with aluminum but should be aware that overheating is a possible complication, which can cause the weld to break and fall to the floor.
Rod welding is often used in the following industries.
Aerospace
Design
Field repair
Production
Shipbuilding and shipbuilding
Mining
Nuclear
Oil
Steel production
Structural welding
Construction of a power plant
As with any welding process, there are advantages and disadvantages. Some benefits:
The necessary equipment is inexpensive.
This can be done both inside and outside.
Different electrodes are used for different metals and are easy to replace.
While this process is best used on thick metals, there are many metals and alloys that can be easily welded using this process.
It can be used on painted and rusty surfaces if the rust is thoroughly cleaned before starting the welding process.
Disadvantages of stick welding
It is difficult to use stick welding on thin metals.
There is sludge that needs to be removed.
The electrodes need to be replaced frequently.
This is a slower process than some other types of welding.
Rod welding is not suitable for reactive metals.