Stick Welder: Amps, Rods and What to Look For
A stick welder (SMAW, or shielded metal arc welding) joins steel with an electric arc struck between the workpiece and a flux-coated steel rod. The flux burns off to shield the weld and leaves a slag crust that you chip away. For home, farm and shop repair, a machine with 120 to 200 A output, a duty cycle of at least 20% at rated amps and DC output covers most jobs, and the rod you choose matters as much as the machine.
What a stick welder does well
- Works outdoors in wind, because the flux makes its own shielding and there is no gas to blow away.
- Welds rusty, painted or dirty steel better than MIG, especially with deep-penetrating rods.
- Welds thick steel, with the right rod and amps.
- Needs no gas bottle or wire feeder, so the machine is simple and portable.
It is harder to learn than MIG on thin sheet, because the rod burns away and you must keep a steady arc gap. For help choosing between processes, see types of welding and what is MIG welding?.
Amps and input voltage
Output amperage sets the thickness you can weld, and the input voltage sets how much amperage the machine can reach.
| Input | Typical output | Suits |
|---|---|---|
| 120 V | Lower amps, often under 150 A | Thin to medium steel, light repair |
| 240 V | 200 A or more | Medium to thick plate, frames, trailers |
Maker specs differ, so check the machine’s rated output at the voltage you will actually use. Rod size and amps go together: 3/32 in rods run at about 70 to 110 A, 1/8 in at 90 to 160 A and 5/32 in at 130 to 220 A. The 7018 welding rod guide lists these ranges with the metal thicknesses.
Duty cycle
Duty cycle is the share of a 10-minute period the welder can run at a given output without overheating, so 20% at 200 A means 2 minutes welding and 8 minutes cooling. Duty cycle falls as amps rise, so read the rating at the amps you will actually use, not at the lowest setting. Short welds with pauses to chip slag rarely overheat a machine, and a low duty cycle matters most when you run long beads on thick plate.
AC, DC and inverter stick welders
| Type | Output | Notes |
|---|---|---|
| AC transformer | AC only | Cheap and tough; harder arc, limited rod choice |
| DC rectifier | DC | Smoother arc, more rod types |
| Inverter | DC (some AC/DC) | Light, portable, smooth arc, often with hot start and arc force |
Hot start gives extra current for the first moment of the arc so the rod starts without sticking. Arc force raises current briefly when the arc gets short, so the rod is less likely to freeze to the work. Both help beginners, and both come as standard on most inverter machines.
Which rod goes with which job
| Rod | Polarity | Best for |
|---|---|---|
| 6010 | DC electrode positive only | Deep penetration, rusty or dirty steel, root passes on pipe |
| 6011 | AC or DC | Same jobs as 6010 on AC machines |
| 6013 | AC or DC | Thin steel, light fabrication, easy arc and soft bead |
| 7014 | AC or DC | Fast fill on clean steel, easy slag removal |
| 7018 | DC electrode positive (7018AC for AC) | Strong structural welds, thick or crack-prone steel |
The first two digits give the weld’s tensile strength in thousands of psi, so 60 means 60,000 psi and 70 means 70,000 psi. Low-hydrogen rods such as 7018 must be kept dry; see 7018 welding rod uses, amperage and storage.
What to look for when buying
- Input voltage that matches your outlet, 120 V or 240 V.
- Rated output amps and duty cycle at that amp setting, not just the maximum.
- AC or DC output, and whether the machine runs the rod you need.
- Weight and portability, if you move it between jobs.
- Arc controls such as hot start and arc force.
- A cable and electrode holder you can actually use: check the length and the clamp.
Safety
- A welding helmet with the right lens shade and flame-resistant clothing are needed every time; see welding safety tips.
- Wear welding gloves and cover skin with a welding jacket or sleeves.
- Stick welding makes smoke and fumes. Weld outdoors or with ventilation, and keep your head out of the plume.
- Chip slag with eye protection on; hot slag flies off the weld.
- Weld on a non-flammable surface, and keep a fire extinguisher nearby.
Related guides
Frequently asked questions
What is the difference between a stick welder and a MIG welder?
A stick welder uses a hand-fed flux-coated rod and needs no gas, so it works outdoors and on rusty or dirty steel. A MIG welder feeds a wire automatically with shielding gas and is easier on thin metal.
Can a stick welder run on 120 V?
Yes, many small units run on 120 V, but they top out at lower amps and suit thin to medium steel. A 240 V machine is needed for thick plate or higher duty cycles.
What does duty cycle mean on a welder?
The share of a 10-minute period the welder can run at a given output without overheating. A 20% duty cycle at 200 A means 2 minutes of welding followed by 8 minutes of cooling.
Is AC or DC better for stick welding?
DC gives a smoother, more stable arc and works with more rod types. AC machines are cheaper and fine for rods such as 6011 and 6013, but low-hydrogen rods like 7018 usually need DC.
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