Welding rod sticking: a detailed guide

Everyone who begins welding eventually wonders why the welding rod sticks to the workpiece during the stick welding process. Indeed, this can result in unpleasant welds and is highly bothersome. The proper stick welding tips to avoid welding rod sticking will be extensively covered in full in this article. Therefore let’s get started.

welding rod sticking

What is stick welding?

With the use of welding equipment and a welder, two pieces of metal can be joined using the stick welding techniques. Shielded metal arc welding and manual metal arc welding are two different names for the same process.

You’ll attach those metal components using an arc created by the welder using either an AC or DC source.

How does stick welding work?

Reading about stick welding might not provide you with all the knowledge you need if you have little experience with it. Because of this, we’ll go over some fundamentals in the sections that follow, such as the types of equipment welders use and the currents you can utilize.

Tools for stick welding

Stick welders themselves are the most essential piece of gear you’ll need in the welding process. A lightweight model with a built-in handle is what we advise even though you can choose from a variety of variants.

The unit is portable, so you can carry it with you anywhere you require it.

In addition, you will need a comfortable helmet. It should cover the highest part of the head and reach the beginning of the neck.

It’s useful to have a mask that elevates so you can see your task, but you may also want an auto-darkening helmet with shields made for different jobs that come with it.

Because they retain the electrode in a suitable position, electrode holders are also beneficial. If the welder you buy doesn’t come with clamps, you can buy one or more of them individually. The majority of welders also have a torch, which is connected by a cable.

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Why does your welding rod stick to metal?

The welding rods sticking to base metal are due to several factors. Some of them are listed below.

Surface characteristics

Welding rod sticking may be a result of the base metal’s surface characteristics. Surfaces that are rusted sufficiently to allow for electrical contact will stick. Clean the area that will be welded of any dirt, grime, or rust using a wire brush.

Inadequately prepared surfaces might cause rods to stick as well. The electrical flow is disrupted by a “capacitor effect,” which occurs when painted surfaces prevent appropriate contact between the base metal and electrical energy.

Arc length

The distance between the weld puddle and the electrode is known as the optimal arc length. It differs considerably if the electrode is positioned wrongly. Electrical resistance and sticking to the workpiece will result from this.

Sticking can be avoided by keeping the length of the electric arc constant throughout the welding operation.

To accomplish this, you must modify the setting to account for the thickness of the material and the welding speed. As there is less metal when welding thinner materials, it is typical for the arc length to lengthen.

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Surface heat and material thickness

While welding a thick piece of metal, sticking issues may also occur if your power supply is insufficient or your torch cable is too short.

This issue emerges because it is more difficult for the heat from the weld pool to spread into the underlying base metal as it gets deeper. Localized melting and excessive electrical resistance/heating are the results.

Ineffective welding methods

Sticking issues can also be brought about by the wrong welding technique. For instance, inadequate arc stability could make it difficult for you to keep control of the electrode.

In some materials, like stainless steel, where significant heat input is necessary, this is especially problematic.

The welding current will follow the least resistance route and stick to the electrode instead of entering the workpiece if the arc cannot be stabilized. Moreover, sticking may happen when thin materials are moved at fast rates. 

Choice of welding electrode

Stick welding problems might also result from employing the incorrect electrode for the job.

Here are some suggestions for selecting the ideal welding electrode:

  • Choose an electrode size based on the thickness of the workpiece: If the electrode is too small, it will be challenging to keep a constant current, and thus the arc length will differ significantly.
  • If the welding electrode is too large for the thickness of the workpiece, it will produce a lot of heat and cling to it.
  • Use electrodes based on the sort of material you’re welding. If the metal you’re welding is unknown or challenging to weld, utilize the electrodes made for that metal. For instance, utilize stainless steel electrodes instead of mild steel.
  • Avoid joining metals that are too similar to one other: When joining metals that are too similar to each other, one of the two is frequently drawn into the gun and melted. Maintaining a short arc length will stop the “arcing-in” phenomenon, which it is called.

Depending on whether AC or DC welding is being used, choose the appropriate electrodes for welding rods.

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The angle of the electrode

Maintaining proper electrode angles when stick welding is one approach to prevent rod sticking polarity.

During stick welding, you should typically keep an angle of 20 to 30 degrees. Sticking and unpleasant welds result from holding the electrode at too high or too shallow an angle. Finding the ideal equilibrium between high and low angles is key.

There are different weld angles for AC and DC.

When using AC, AC welders normally retain the previously specified electrode angle of between 20 and 30 degrees. For DC welders, the majority of manufacturers advise keeping the electrode angle at roughly 45 degrees.

This variation in weld angles results from the different polarity, as will be discussed below:

  • AC has a positive electrode and a negative ground. To maintain consistent polarity, an angle of 20 to 30 degrees must be established on the electrode.
  • DC has a positive electrode and a negative ground, as was previously stated, and its polarity is constant. The rod won’t adhere to the base metal if the angle is kept at 45 degrees.

Preheating

Preheating can be utilized for metals that are challenging to weld or that are brittle and aged. Before welding, preheating involves producing heat with an open flame.

Torches powered by acetylene or propane can be used for preheating (induction heating). Since too much heat can damage the metal, it is often only done for brief periods.

Be careful not to overheat items for an extended length of time as this can result in warping and cracking.

Size of the contact tip

While welding, you should keep the distance between the contact tip of the electrode and that point between 0.3 and 0.5 inches. This gap must not be too large or too narrow to prevent sticking on your metal. For optimum results, make sure the gap is configured appropriately.

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How do you not stick when welding?

The majority of rod sticking occurs as you attempt to strike the arc, and to a lesser extent when running the bead. The causes of these occurrences have been earlier stated. Let’s now discuss ways of prevention.

Select appropriate current settings

Verify that you are employing the correct amperage. The current is sufficient to cause the electrode’s tip to melt, but not sufficient to properly strike an arc. It should be based on the electrode diameter.

Various kinds of electrode rods are made to operate at various amperage levels. The 6010, 6011, 6012, and 6013, for instance, may function at low current levels.

On the other hand, large amperage values are required for 7018 and 7024 type rods to initiate an arc.

It is apparent that the rod thickness also affects the amperage value. It takes more current to melt a thick electrode. The kind of electrode and the type of weld should therefore be taken into account when choosing the optimal amperage settings.

When striking an arc, your electrode gets sticky in case of low amperage, your arc will keep slipping while retaining the proper arc length, or the arc will stutter. Any electrode can be used to strike an arc.

To guarantee that the filler rod doesn’t adhere to metal, you can occasionally slightly boost the current above the range when your circuit’s resistance is a bit high.

Furthermore, remember that when the electrode’s tip glows, too much current is being delivered. With the rod you’re using, attempt to refer to the producer’s amperage range.

Maintaining cleanliness on the electrode’s surface and utilizing the proper rod size

Check that the electrodes are in good condition before starting by checking for rust or degradation. Using your fingertips, try rubbing the flux off the rod.

The electrode gets more sticky if the flux freely detaches from the rod, indicating poor quality. You should not use these subpar rods

If the weld needs to have good consistency, select a larger rod because they have the highest deposit rate. The type of the weld must also be considered when determining the size of the electrode to employ.

Remove any corrosion, dampness, grease, or other impurities from the surface of the filler metal before welding.

Although stick welding is more forgiving in certain circumstances, doing this will prevent you from running into unforeseen difficulties.

Ensure an effective ground connection

The circuit’s overall resistance may increase if the base metal has a weak connection to the ground. It will be challenging to ignite an arc when the open circuit voltage is low due to high resistance. Ensure that your ground connection is solid.

Check the ground wire for any cracks. The cable should be severed at both ends and new joints should be made if the terminal connections have become excessively rusted.

Remember to ensure that all of the stick welding leads are appropriately attached to what you’re utilizing them for.

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Use proper arc length

It appears normal to use an excessively long arc when initially trying to stick weld, perhaps to help in getting a clearer perspective of the arc and puddle.

If you’ve been able to maintain a stable arc, strive to ensure the base metal and rod tip are at a reasonable distance from one another. When avoiding touching the metal, endeavor to keep the distance short.

If the electrode appears to have become stuck in the weld pool, the length of the arc is likely to be short.

Also, avoid extensively increasing the length of the arc during the welding process because this will make the metal splatter indiscriminately.

Always keep it below the electrode diameter metal core.

The arc length can be impacted by the welding position as well. To help manage the weld puddle, a vertical-up weld, for instance, will typically require a tighter arc.

Too close electrodes decrease welding voltage and risk being buried in the molten weld puddle, which will extinguish the arc. An electrode that is too distant away produces a wide arc, which means that insufficient deposited weld metal stays at the joint, inhibiting penetration.

Maintain the travel speed and angle at the proper levels

You should be conversant with the standard welding positions. To ensure that the weld is consistent right up until the very last second, ensure you are in a calm position.

To steady the electrode, for instance, place your left elbow on the workbench while maintaining the welding rod holder in your right arm. In this manner, you may easily maintain the same travel speed and angle.

What to do when welding rods stick?

When the welding rod sticks, give the electrode holder a brief, quick jerk if the electrode gets trapped. Never allow it to stay too long. As soon as you realize your electrode is caught, try to remove it because it will continue to take current and heat up.

If the electrode doesn’t come out after the initial jerk, twist it back and forth to help it loosen. The initial jerk would have made it looser. A few more would be sufficient to pull it off.

In certain operations, the electrode cannot be reactivated and utilized again if any part of it was not used in the initial arc strike.

If the rod still won’t come off, loosen it while simultaneously pressing the rod’s release lever. It ought to come off this way.

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Which welding rod is the easiest to use?

The easiest welding rod to use is electrode number 7018 because of its thick flux and high content. With the least amount of spatter and with good arc penetration, these welding rods create the cleanest, smoothest, most stable, and most consistent arc. Several welders may use these in the construction of structures. They generate a clean arc with little splatter.

Does welding with too much current causes the electrode to stick?

Yes. Occasionally, there are warning indications before the real sticking of your electrode to the metal. A few of these include:

  • Poor quality welds. When the arc length is excessively long, electrodes frequently become caught, which results in heat loss from the electrode and lower-quality welds.
  • Sputtering and spitting. When the welding pace is too slow or the welding area has a lot of moisture, electrodes frequently become caught. Using excessive SSP (slag-protecting gas) is typically the cause of a lack of fluidity (or sticking).
  • Untimely ignition. Typically brought on by spattering. It happens when metal fragments shoot out of the tip, which allows small pieces of base metal that are yet to molten to ignite prematurely.
  • Inadequate penetration. Lack of fluidity can sometimes cause sticking, as can using too much amperage for the thicknesses involved. If the amperage is too high, the electrode begins to stick.
  • Electrode sticking to the workpiece. It also results from moisture building up on the electrode that transfers to metal while welding, which typically occurs when gloves are not worn.
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Conclusion

Due to its simplicity of usage and ability to generate a stable arch, stick welding ranks among the popular types of welding.

If you’re new to this sector, you can take on an apprenticeship to learn from experienced workers, and you can also use this article to acquire stick welding tips you can apply to your work. But remember that perfecting a stick weld requires a bit of practice.

After reading this article, you should feel more confident when dealing with these circumstances.

Learn More: Five Steps to Improving Your Stick Welding Technique

Aron Russell

If you have come to my page, then you are trying to learn the correct technique for welding various parts. I can confidently say that you can trust me. I have been studying multiple welding techniques for 20 years. In my youth, I got a job at a factory, where my acquaintance with this technique began.

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