Stick or Buzzbox Welders – Stick Handling

Also known as buzzbox welders, stick/SMAW welding machines are fairly straightforward devices – they are converter boxes which create high amperage current with a low voltage out of low amperage current with a high voltage, then feed it to the welding gun, where it passes through the flux-coated filler metal electrode and into the workpiece, creating an electric arc. The three versions of buzzbox welders are the alternating current (AC), direct current (DC), and hybrid varieties, the last type able to switch back and forth between current types.

In choosing a stick/SMAW welding machine for your portable welding projects, you will need to balance cost against effectiveness in your purchase decision. AC machines are very cheap, but are more difficult to use, more limited, and feature unstable arcs. DC machines are more costly, but are far more adaptable to circumstance, with the ability to weld different thicknesses and positions of metal as well as creating a more stable and reliable electric arc.

The sticks themselves – also known as electrode rods, welding rods, and so on – are sections of filler metal coated in a heavy, shielding-gas-generating flux, which are inserted into the welding gun and function as filler, electrode, and shielding gas supply at the same time. It is this combination of factors which make stick/SMAW welding machines suitable for outdoor use, as well as making their setup at a work site quick and easy compared to other types of welders, including MIG welders, which are generally used as a benchmark for welding ease.

The electrode sticks range from 9” to 15” long, and 1/16” to 3/8” thick. The size is chosen depending on the specific job which is underway. The process of stick welding does not function properly on metals thinner than 1/8”, so sheet metal welding is best accomplished by other means. The stick applies a flux slag coating to the weld as well, which helps to protect against oxidation but also needs to be removed between weld passes in multiple-pass welds. The last layer of slag also needs to be removed as part of the process of completing the weld.

The sticks are used up as the welding proceeds, and it is necessary to replace them periodically during the welding process. There is a risk of death by electrocution when adding a new stick, so you should be very careful when doing so. Do not change the stick with either the electrode or the welding gun in contact with metal, especially the metal you are welding, since a circuit will be completed through the welding clamp and your body. Similarly, use dry gloves to remove the old stub and insert the new stick – and do not do so if you are wet or if it is raining. Try to stand on a dry surface as well.