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What Is SMAW Welding?
A comprehensive guide to Shielded Metal Arc Welding, one of the most trusted welding methods worldwide
Shielded Metal Arc Welding, also known as SMAW or stick welding, is one of the most widely used welding methods in the world. It’s a process where an electric arc forms between a coated electrode (the “stick”) and the metal workpiece, melting both to create a strong, fused joint. Despite being over a century old, SMAW remains a trusted method in construction, pipeline work, shipbuilding, and repair industries.
In this guide, you’ll learn how SMAW works, why it’s still relevant, and what the research says about its performance.
A Brief History of SMAW Welding
SMAW was first developed in the late 1800s. Russian engineer Nikolay Slavyanov introduced the concept of arc welding in 1888, and Charles L. Coffin later improved the method with a coated metal electrode. Since then, the technique has been used worldwide for joining ferrous and non-ferrous metals in everything from skyscrapers to submarines.
How SMAW Welding Works
SMAW uses a flux-coated electrode to conduct current from the welding machine to the metal pieces being joined. When the electrode touches the metal, it creates an electric arc that produces temperatures over 6,000°F. This intense heat melts both the base metal and the tip of the electrode, forming a weld pool.
The flux on the electrode decomposes into gases that shield the molten pool from oxygen and moisture in the air. This prevents contamination and oxidation. The flux also forms a layer of slag on top of the weld, which protects the metal as it cools and solidifies.
Components of SMAW Equipment
- Welding Machine: Provides either AC or DC constant current
- Electrode Holder: Clamps the consumable electrode
- Ground Clamp: Completes the circuit
- Electrodes: Flux-coated sticks like E6010, E6011, or E7018 are used for different materials and positions
Advantages & Disadvantages
Advantages of SMAW
- Simple and portable setupWorks in outdoor and windy conditions
- Low equipment cost
- Suitable for thick metal sections
- Great for repair and maintenance work
Disadvantages of SMAW
- Simple and portable setupWorks in outdoor and windy conditions
- Low equipment cost
- Suitable for thick metal sections
- Great for repair and maintenance work
Applications of SMAW Welding
SMAW is commonly used in:
- Construction (steel beams and structures)
- Oil and gas pipelines
- Shipbuilding and marine structures
- Agricultural equipment
- Railways and heavy machinery maintenance
In some regions, SMAW accounts for more than 50% of all welding performed, especially in field repairs and remote job sites where portability is crucial
(Source: Wikipedia).
Welding Parameters and Their Impact
Welding current, voltage, and speed all affect the quality of a SMAW weld. One research study on SA 516 Gr. 70 steel showed that increasing welding current from 50 A to 70 A improved both tensile strength and hardness. The best performance came at 70 A, though smaller grain size and fine microstructure appeared at lower current levels
(Read the full study on ResearchGate).
Another study reviewing mild and stainless steel frames found that both travel speed and amperage significantly impact weld strength, ductility, and hardness
(View mechanical properties study).
Common Weld Defects in SMAW
- Porosity: Caused by trapped gases in the weld
- Incomplete fusion: Poor joint bonding due to low heat
- Cracks: Often due to high stress or improper cooling
- Undercut: Groove along the weld toe that weakens the joint
These issues are typically caused by improper settings or technique. Proper training and electrode selection can minimize defects.
SMAW and Environmental Safety
SMAW welding does produce metal fumes, including iron, manganese, and small amounts of other elements. According to the Rhode Island Department of Environmental Management, good ventilation, PPE, and fume extraction systems are critical to keep welding safe.
Is SMAW Still Relevant Today?
Despite newer technologies like MIG and TIG, SMAW continues to thrive, especially in fieldwork where portability and ruggedness matter. It’s especially favored for its simplicity, low cost, and versatility across multiple positions and metal types.
Educational programs across the country still include SMAW as a core module. For example, the Kansas Board of Regents welding course includes SMAW training as part of its foundational welding certification.
Is SMAW Still Relevant Today?
SMAW welding may seem old-school, but it’s still a powerful tool in the right hands. Whether you’re building steel infrastructure or repairing a broken plow in the field, stick welding offers dependable results with relatively simple equipment. Research continues to evolve the technique with new electrode coatings and better current control strategies.
I recommend anyone starting a welding career to master SMAW. It teaches fundamentals that apply across all welding methods and builds the hand control and technical insight needed to succeed in the trade.