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745 Welding, Cutting, and Brazing Safety
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745 Welding, Cutting, and Brazing Safety

Arc Welding/Cutting Equipment

Shielded Metal Arc Welding (SMAW / Stick Welding)

Shielded metal arc welding is among the simplest and most common welding/cutting processes, using consumable electrode rods coated with flux to protect the weld area from contamination, ideal for outdoor and heavy industrial use.

What is Stick Welding

Equipment includes: Welding power source, electrode holder, electrodes, cables, ground clamp, helmet, PPE.

Operation Steps: The following is a brief list of steps to safely operate the equipment:

  1. Inspect Equipment
    • Check welding machine, cables, electrode holder, and ground clamp for damage.
    • Verify connections are secure and in good condition.
  2. Set Up Machine
    • Select the correct type and size of electrode for the job.
    • Set the correct welding current (amperage) on the machine based on electrode and material.
  3. Prepare Work Area
    • Clean the base metal to remove rust, paint, oil, and dirt.
    • Ensure proper ventilation to remove welding fumes.
    • Set up welding screens to protect others from arc flash.
  4. Strike the Arc
    • Clamp the workpiece securely.
    • Insert electrode into holder.
    • Touch electrode tip to the workpiece, then lift slightly to start the arc.
  5. Weld the Joint
    • Maintain correct arc length (about the diameter of the electrode core).
    • Move steadily along the weld joint with a consistent speed and angle.
    • Watch the molten weld pool to control bead shape and penetration.
  6. Finish and Shut Down
    • At end of weld, break the arc by quickly lifting electrode away.
    • Allow weld to cool slightly, then chip away slag with chipping hammer and brush with wire brush.
    • Turn off welding machine when work is complete.

Safe Operation Guidelines: The following safe procedures and practices help prevent welding injuries and illnesses:

  • Always inspect electrode holder, cables, and connections for damage.
  • Ensure proper grounding and insulation.
  • Check welding environment for fire hazards and remove combustibles.
  • Always wear proper PPE (auto-darkening helmet, leather gloves, jacket, safety boots).
  • Provide proper ventilation; use exhaust fans or respirators as needed.
  • Avoid welding in wet conditions to prevent electrical shock.
  • Keep electrode holder insulated and dry at all times.
  • Turn off machine before replacing electrodes or making adjustments.

Knowledge Check Choose the best answer for the question.

4-4. Why is it unsafe to weld in wet conditions when using SMAW?

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