What is

Electrode Welding?

Simple, versatile, effective 

Electrode welding (also known as manual arc welding, stick welding, or E-hand welding) is usually the first welding process that professional welders learn during their training. It is easy to learn, but already provides insights into how welding machines work and the relationship between metals and electrical voltage.

Welding with a stick electrode offers numerous advantages over MIG/MAG and TIG processes. In principle, almost all materials can be welded with an electrode. The process is mainly used in steel and pipeline construction, but also in metalworking and the metal industry. Manual metal arc welding allows for any type of weld seam and position, whether in awkward or overhead positions, vertical or vertical downwards welding. In addition, welders are independent of protective gases and can work outdoors without any problems, even in unfavorable weather conditions such as wind or rain.

Electrode hand welding

Manual metal arc welding: this is how it works

In electrode welding, contact between the rod electrode and workpiece ignites the arc. This creates a short circuit for a fraction of a second between the two poles, meaning that current can then flow. The arc burns between the workpiece and the electrode. This creates the required fusion heat. Via the consumable core wire and the coating, which is also consumable, the electrode also supplies the protective slag and the gas shroud.

Manual arc welding requires a low voltage and a high amperage. The welding system converts the available mains voltage into a significantly lower welding voltage. At the same time, it provides the required amperage, which also allows the power source to be adjusted and regulated.

In manual metal arc welding, the amperage is the most important parameter for the quality of the connections. It must therefore remain as constant as possible, even if the arc length changes. In order to ensure this, power sources for electrode welding always have drooping characteristics.

Arc hand welding
System design electrode welding

Electrode welding system structure

(1) Main connection

(2) Power source

(3) Welding power-lead (electrode)

(4) Grounding cable (workpiece)

(5) Electrode holder

(6) Earthing clamp

(7) Rod electrode

(8) Workpiece

Advantages of electrode welding

  • Easy handling
  • Can be used universally, irrespective of location
  • Easy to learn
  • Low noise
  • Low procurement costs
  • Protection of the weld seam due to slag formation
  • Not sensitive to contaminations such as rust, scaling, oils or grease
  • Almost all metallic materials can be welded
  • High weld seam quality and high mechanical properties

Disadvantages of electrode welding

  • Low welding speed
  • Heavy smoke development
  • Occurrence of blowholes
  • Increased susceptibility to errors due to end craters and flash points
  • Electrode diameter must be adapted to sheet thickness and welding position
  • Drying standard-packaged electrodes causes high setup and downtime
  • Time-consuming preparation and follow-up work such as clamping the electrodes and removing residual stubs, slag, and spatter
  • Cannot be mechanized

Innovative welding systems for manual metal arc welding

Ignis Battery 150

  • Perfect arc stability without power connection
  • Three different operating modes: battery operation, generator operation, charging and welding in hybrid mode
  • 84 battery cells, 750 Wh, no memory effect, low self-discharge
More about the Ignis Battery
Ignis 180

Ignis 180

  • Mobile and robust
  • Full power even with long grid leads
  • Easy and user-friendly operation
Find out more about Ignis 180
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Protective clothing for welding professionals
Everyday welding work presents many challenges: UV radiation and welding fumes can pose a health hazard without suitable protection. The right equipment and appropriate clothing make all the difference here.

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