Stick welders explained: simple machines, real limits

A stick welder is the simplest arc welder there is: a power source, a ground clamp and a rod holder. There is no wire feed, no gas and very little to go wrong, which is why it remains the farm and field repair tool.

Stick suits thick steel, outdoor work and metal that is not perfectly clean. It is harder to learn than wire feed welding and poor on thin sheet. The numbers to check are the same as any welder: rated output with duty cycle, and input current.

Striking and running a rod

You clamp a coated rod, about a foot long, in the holder and scratch or tap it on the work to strike the arc (the electrical discharge that melts the metal). The rod melts into the joint as filler. The coating burns into a gas shield and a layer of slag that protects the cooling weld. When the rod is down to a stub, you stop, fit another, chip the slag and carry on. Compared with the other processes in mig vs tig vs stick, it is the most portable and the least tidy.

Rods and amperage

Rods are named by a code such as 6011, 6013 or 7018. The code describes strength class, welding position and coating type. In everyday terms:

• 6011 digs deep and tolerates rust and paint. Runs on AC or DC.
• 6013 is soft and easy to run, with light penetration. A common learning rod.
• 7018 gives smooth welds and is widely used for serious work. It is a low hydrogen rod and must be kept dry, and it is fussier to start.

Each rod diameter has an amperage range printed on the box by its maker. Thicker rods need more current. That range, more than the badge on the machine, tells you how much welder you need: a machine must deliver the rod’s current at a usable duty cycle. A separate guide to rods is planned. Until then, use the range on the box.

Reading a stick welder listing

Check	Why
AC, DC or both	Decides which rods you can run
Rated output and duty cycle	A rod burns for a minute or more, so stick leans on duty cycle harder than short mig welds do
Input current at each voltage	In manuals we have read, stick often draws the most. The YesWelder MCT-520 lists a 45 amp maximum on 110 volts in stick mode
Hot start, arc force, anti-stick	Inverter features that make striking and holding an arc easier
Lead length and clamp quality	Short leads and weak clamps are common complaints on budget machines
Lift tig	Many DC stick inverters can run basic tig with an added torch and argon

Input figures for several machines are in the welder comparison table, and the background is in welder amp draw.

Stick-only, or multiprocess?

A stick-only inverter is small, light and the cheapest welder you can buy. If you also want wire feed, a multiprocess machine includes stick mode, so you do not need both. Our multiprocess roundup lists stick output for each pick.

Safety notes specific to stick

Stick throws more sparks and slag than other processes and makes heavy fume. Hot rod stubs start fires, so drop them in a metal can. Chipped slag flies, so wear safety glasses under the helmet. Use the stick rows of the helmet shade chart, which run darker at high current. The full gear list is in welding for beginners.

Stick is the process most often used for repairs on heavy equipment and trailers. That does not make those jobs beginner work. Anything that carries a load or holds pressure belongs to a certified welder.