2 minute read
Master of Metal
Master of Metal
A Look at Stick Welding
If you’ve ever seen somebody welding, chances are the technique they’re using is stick welding. It’s the oldest form of welding there is, and despite its age, it's still immensely popular. But it’s also a risky technique that doesn’t always provide satisfactory results.
This begs the question: how has it endured?
Actually, the first question is, “What is stick welding?” It’s the informal term for shielded metal arc welding, aka SMAW. It’s a manual arc welding process that uses a flux* powered by a consumable electrode. An electric current is generated from the electrode and a power supply to create an electric arc with the metals being welded. As the electrode and metal melt, they fuse, with the flux creating both shielding gas vapors and slag to protect the weld even further. It is primarily used for iron and steel welding.
Stick welding has its roots in the 1800 discovery of the short-pulsed electric arc by Humphry Davy. Two years later, Vasily Petrov would discover the continuous electric arc. Little changed in the world of electric welding until 1881, when Auguste de Meritens developed and patented a carbon arc torch. This led to the development of carbon arc welding in 1885, with the first version of the electrode holder appearing two years later. The consumable electrode appeared in 1888, thanks to Nikolay Slavyanov.
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P R O D U C T I O N
Two variations of stick welding exist, but neither has enjoyed the popularity of the original. Gravity welding is an automated version, created by K.K. Madsen in 1938. It did have some success in Japanese shipyards of its day, but in the modern age, its applications are few. Firecracker welding was developed around the same time in Austria. In the same vein, there is laser welding, which is primarily used for cutting or tooling due to the intense heat.
Stick welding is simple to master and applicable to all kinds of projects, attributing to its popularity. In some countries, it accounts for over half of all welding. It’s especially prominent in the repair and maintenance industry since its downsides are less prevalent there. Yes, there are issues with sick welding- quite a few, in fact. The end results of the welding are often unsightly and require extra cleaning.
Another major concern is porosity, which could weaken the weld over time. It’s often invisible to the naked eye and requires specialized equipment. It’s also possible for the fusion itself to be weak and eventually crack. Finally, like all other welding techniques, SMAW is dangerous if not done properly. Without training and protective equipment, it’s easy to gain burns, exposure to poisonous gas, or even burned retinas due to the intense light of the welding arc.
Other forms of electrodes were briefly used during this period, but most were expensive and didn’t mesh well with the inexpensive nature of stick welding. For example, A.P. Strohmenger and Oscar Kjellberg unveiled their coated electrodes around 1900. The complex production at the time was, unfortunately, too much extra effort. In 1972, however, the extrusion process being introduced lowered the cost of coating electrodes and gave manufacturers access to more complex mixtures for specific tasks.
Nevertheless, stick welding is likely going to remain a popular welding method. There are dangers and downsides, but this is true of most welding techniques. SMAW is easy to master and inexpensive to complete, both of which are huge boons to both professionals and the companies who hire them. Besides, it’s just cool. How often do you get to say you harnessed the power of electricity to bond metal?
*A flux is a chemical cleaning/flowing/purifying agent.
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