Beginner's Guide to Shielded Metal Arc Welding (SMAW)

If you’re interested in welding and have wondered, “What is SMAW?” we’re here to help explain.

SMAW stands for shielded metal arc welding — a type of welding used in a variety of industries, including maintenance and repair, construction, industrial fabrication and more. It’s one of the oldest types of welding, dating to 1890 when Charles L. Coffin patented the process.

SMAW welding is also one of the welding processes students learn in the Welding Technology program at Universal Technical Institute (UTI), in addition to GMAW, GTAW and FCAW. Afterward, they can pursue welding roles to use these skills in both repair welding and production, and across all welding positions on all ferrous metals.

Want to learn more? Keep reading. We’ll offer an introduction to SMAW, its unique applications and how to build shielded metal arc welding skills through industry-aligned technical training!    

Key Summary Points

• SMAW stands for shielded metal arc welding and is one of the oldest types of welding.
• SMAW, also known as stick welding, uses a flux-coated electrode to form the weld and does not require an external shielding gas.
• SMAW can be used for a variety of applications and on different alloys and metals.
• SMAW equipment is portable, versatile and has a lower equipment cost compared to other welding methods.
• While SMAW has advantages such as built-in shielding and versatility, it also has disadvantages including lower productivity and more cleanup required.

What is SMAW Welding?

Shielded metal arc welding (SMAW), commonly referred to as stick welding, is a manual arc welding process that uses a consumable electrode coated in flux to lay the weld. An electric current, either alternating current (AC) or direct current (DC), is used across the electrode, creating an arc between the electrode and the metals to be joined. As a result, the electrode and the base material are melted (or welded) together. It’s one of the most commonly used welding processes.

Stick welding

SMAW is also known as stick welding because of the flux-coated electrode used during the welding process. This electrode is a metal stick or rod held in an electrode holder connected to a power source, which is used to form the weld. Electricity passes through the electrode and touches the base metal.

Meanwhile, the flux forms a gas that shields the electric arc between the electrode and the metal being welded. This prevents contamination from atmospheric gases and makes SMAW, unlike GMAW, suitable for working outdoors.

How SMAW Works

Now that you know the basics of what SMAW welding is, here’s how it works.

SMAW process

SMAW uses the heat of the arc to help melt the top of a consumable covered electrode and base metal. Both the electrode and item being welded are a part of an electric circuit. This circuit also includes the power source, welding cables, electrode holder and ground clamp.

The cables from the power source are attached to the work and electrode holder. Welding begins when an arc forms between the base metal and tip of the electrode. Then, the surface of the work and electrode tip are melted.

Metal then forms on the end of the electrode, transferring from the arc into a pool. Filler is deposited when the electrode is consumed. The arc in SMAW gets extremely hot, with temperatures that can exceed 9,000 degrees Fahrenheit!

SMAW voltage

Voltage is one of the main variables in arc welding. Some welding processes are able to use a preset constant-voltage system to maintain this, but with SMAW welds, voltage is regulated manually. This is done by moving the stick closer to or farther from the work.

SMAW welding current

Constant current power sources are used for most SMAW and other manual welding processes. This provides a consistent preset current and maintains the amperage setting.

SMAW polarity

With SMAW welding processes, reverse polarity is almost always used. It helps provide the best bead profile and penetration and it reduces excessive spatter, which are droplets of molten material that are generated at or near the welding arc.

SMAW components

Some of the basic tools used when stick welding include:

• Arc welding power source (welding machine)
• Electrode lead cable
• Electrode holder
• Leads
• Cables
• Cable connectors
• Ground clamp
• Chipping hammer

As with any other welding process, safety equipment is used by the welder. This includes a helmet, gloves and protective clothing.

What Is SMAW Used For?

SMAW can be used for a variety of metal types and various thicknesses. It is often used for heavy-duty work involving industrial iron and steel, like carbon steel and cast iron, as well as work involving low- and high-alloy steels and nickel alloys. SMAW is used in a variety of industries, including:

• Construction
• Pipelines
• Shipbuilding
• Underwater welding
• Farm machinery manufacturing

SMAW equipment is easily portable and can be used in a variety of environments, from indoors to outdoors to on a ship at sea. And even though SMAW is one of the oldest forms of welding, new technology is always advancing processes and making them increasingly more efficient.

With enough skill, SMAW welders can accurately choose the correct electrode, weld speed and arc length, which is needed for reliable welding across a variety of industries.

Advantages of SMAW

There are several advantages to SMAW welding, including:

• Lower equipment cost: Compared to equipment used for other welding methods, SMAW equipment is usually simple and inexpensive.
• Lightweight and portable: SMAW equipment is easy to transport, which adds to its convenience.
• Built-in shield: Since the flux-covered electrode generates its own protective gas, no additional exterior shielding gas is needed, which means SMAW can be done outdoors.
• Versatile: SMAW can be used on a variety of different alloys and metals, as well as in numerous positions.

Disadvantages of SMAW

While there are many advantages to the SMAW process, the method has its disadvantages too:

• Lower productivity rate: Unlike semi-automatic or automatic welding processes, SMAW is manual, which can translate into lower productivity.
• Less deposition: Deposition is the amount of welding material deposited per unit of time, and SMAW projects have a lower amount in comparison with others.
• Spatter and slag cleanup: With SMAW, slag (a layer of byproduct) needs to be removed after welding. It can also produce more spatter, which can make it a messier process.

Even though SMAW is one of the most common types of welding techniques used, it requires skill and training to pull off clean, quality SMAW welds.

SMAW FAQs

1. What does SMAW stand for in welding?

SMAW stands for “shielded metal arc welding.”

2. What is the difference between SMAW and stick welding?

SMAW is commonly referred to as stick welding due to the flux coated electrode that has a metal rod (aka “the stick”) at the core.

3. What is the difference between GMAW and SMAW?

Gas metal arc welding, or GMAW, uses an electric arc formed between metal and wire electrode. A continuous solid wire electrode is sent through the gun and a shielding gas protects the process from getting polluted with contaminants in the air.

On the other hand, SMAW uses a flux-covered electrode that produces a gas shield when heated, so it doesn’t rely on an external gas like GMAW. SMAW welders also require new electrodes periodically, while GMAW welders are constantly and automatically fed electrodes.

4. What are the disadvantages of SMAW welding?

One of the main disadvantages of shielded metal arc welding (SMAW) is the lower deposition rate compared to other welding processes, which can make it less efficient for large projects. Additionally, SMAW produces significant slag, which needs to be cleaned between passes, adding extra time and effort to the welding process.

5. What materials can be welded using SMAW?

SMAW can be used to weld a variety of materials including carbon steel, stainless steel, cast iron and low-alloy steel. It’s also versatile enough to weld some nonferrous metals such as aluminum and copper alloys, although this requires specific electrodes.

Take SMAW Welding Classes at UTI

If you’re interested in learning the SMAW process as well as other valuable welding techniques, attending the Welding Technology program at UTI can help.¹ The program takes just 36 weeks from start to finish.

In courses like Shielded Metal Arc Welding I and II and Welding Applications, students learn how to:

• Set up and use SMAW equipment and accessories
• Identify modes of metal transfer and various rods/electrodes appropriate for specific weld types
• Perform basic SMAW welding positions
• Perform horizontal, vertical and overhead welding operations
• Correctly maintain and service a SMAW welder
• Build specific SMAW weld projects

Students also learn how to use hand tools and machines they’d find in a shop environment during their coursework, which is critical in a welding skill set.

“The curriculum utilizes real-life situations, which prepares students for work they would see in a welding profession,” says Brian Masumoto, welding instructor at UTI Rancho Cucamonga. “Students are taught how to diagnose problems they might come across on the job. We also teach the students how to pass a welding certification test by actually performing a test.”

Welding Campus Locations

Learn more about SMAW welding and other major arc welding processes at UTI. When you attend one of the UTI campus locations offering the program across the country, you’ll get the training and hands-on experience you need for a career in welding.

Find out more about each individual location by clicking the links below:

• Avondale, Arizona
• Long Beach, California
• Rancho Cucamonga, California
• Sacramento, California
• Miramar, Florida
• Lisle, Illinois
• Bloomfield, New Jersey
• Mooresville, North Carolina
• Exton, Pennsylvania
• Austin, Texas
• Dallas/Fort Worth, Texas
• Houston, Texas

In just 36 weeks, you can graduate from one of these campuses.    

Welders are in demand. So if you’re interested in pursuing a career in this thriving field, request more information online or call 1-800-834-7308 to contact an Admissions Representative today.