Strike and Control an Arc with Stick Welding

A. Finished-Project Specification

Outcome: one or more flat mild-steel practice coupons showing repeatable arc starts and short controlled beads, produced at a recorded polarity, electrode, and amperage, with slag removed, brushed, and visually inspected against Section D. This chapter does not produce a joint, fillet weld, or finished fabrication.

B. Component Schedule

Component	Quantity	Material	Finished Size	Preparation
Practice coupon	1 or more per learner, per approved procedure	Identified mild steel, from Chapters 4–6	As prepared and inspected in Chapter 6	Clean bright metal, flat, deburred, marked with start lines and endpoints per Step 14 below
Practice electrode	As consumed during practice, per approved procedure	Approved SMAW classification identified by the instructor or shop procedure	Diameter as specified by the approved procedure	Dry, undamaged, identified coating; free of moisture, cracks, chips, and contamination

C. Material Takeoff

• Coupon stock: flat mild-steel coupons carried forward from Chapters 4 through 6; no new cutting or prep is performed in this chapter.
• Electrodes: the classification and diameter identified in the approved SMAW procedure; quantity sufficient for the number of arc-start and short-bead repetitions specified by the instructor or shop procedure.
• Consumable handling: return unused electrode stubs and partial electrodes to approved dry storage; do not mix classifications in the same storage container.

D. Acceptance Standards

Check	Standard
Machine setup	Polarity, electrode, and amperage match the approved procedure and are recorded before the first arc is struck
Work-clamp connection	Attached to clean sound metal close to the practice area; does not pass through bearings, hinges, electronics, or unintended components
Arc start	Arc is established using the approved start method without a stray arc strike outside the marked start area
Arc length	Consistent with the approved electrode guidance throughout the bead
Travel and bead profile	Steady travel speed, continuous bead, without excessive width variation
Termination	Crater filled using the approved method; no abrupt break or crack at the stop
Cleaning	Slag fully removed and bead wire-brushed before inspection
Visual inspection	Free of arc strikes outside the start area, excessive porosity, undercut, and incomplete fusion at the start

E. Preparation — Setup Review

1. Review the approved SMAW practice procedure, coupon, electrode, polarity, position, and starting range. Confirm the procedure matches the station and material staged for this session.
2. Complete the welding-area, fire-watch, ventilation, and PPE checks. Reconfirm the Chapter 1 readiness record and Chapter 2 PPE inspection before proceeding.
3. Inspect the power source, leads, electrode holder, work clamp, and input connection. Confirm no item shows damage identified in the Chapter 3 equipment-readiness record.

F. Machine and Consumable Setup

1. Verify the machine is de-energized before changing output connections. Confirm the disconnect or power switch is off before touching output terminals.
2. Connect the electrode lead and work lead to the approved polarity. Match the connection to the polarity specified in the approved procedure.
3. Attach the work clamp to clean sound metal close to the practice area. Confirm firm contact on bare, unpainted metal.
4. Confirm the clamp path does not pass through bearings, hinges, electronics, or unintended components. Trace the clamp path visually before continuing.
5. Select the approved electrode classification and diameter. Match the electrode to the approved procedure exactly.
6. Inspect the electrode coating for moisture, cracks, chips, contamination, and damage. Set aside any electrode that fails inspection.
7. Keep electrodes dry and identified. Return unused electrodes to approved dry storage between uses.
8. Set the machine to the approved starting amperage. Use the value specified by the approved procedure; do not estimate.
9. Record machine, polarity, electrode, diameter, and setting. Complete the station and coupon record in the Reference Conventions section before striking an arc.

G. Coupon Positioning and Marking

1. Position the coupon flat on a stable welding table. Confirm the coupon cannot shift during welding.
2. Mark short start lines and bead endpoints. Use soapstone or an approved marker to lay out each practice repetition before welding begins.
3. Assume a stable body position with clear lead movement. Confirm the electrode lead can move through the full practice path without tension or drag.

H. Arc Initiation

1. Insert the electrode into the holder with adequate exposed length and secure grip. Confirm the electrode is held firmly and cannot rotate or fall from the holder.
2. Keep the holder insulated from the table and work when not welding. Place the holder in the insulated rest between beads.
3. Lower the helmet before contacting the electrode to the work. Confirm the helmet is fully lowered and the lens is functioning before arc contact.
4. Practice the approved scratch or tapping start on a marked area. Repeat the start motion until it is consistent before recording a graded attempt.
5. Break a stuck electrode by the approved motion without lifting the helmet. Use the release motion specified by the approved procedure or instructor.
6. Stop and isolate power if the electrode cannot be released safely. Do not force a stuck electrode by hand while the machine is energized.

I. Short-Bead Travel and Termination

1. Establish the arc and move immediately into the short practice path. Avoid dwelling at the start point once the arc is established.
2. Maintain arc length according to the approved electrode guidance. Adjust hand position, not amperage, to hold arc length steady.
3. Observe the arc, puddle, and slag relationship rather than staring only at the bright center. Watch the puddle edges and trailing slag to judge travel speed.
4. Maintain the approved work angle and travel angle. Hold both angles steady through the short bead.
5. Move at a steady travel speed. Avoid speeding up or slowing down mid-bead.
6. Terminate the short bead using the approved crater-control method. Fill the crater before breaking the arc.
7. Lift the electrode clear and place the holder in the insulated rest. Confirm the holder is fully seated in the rest before releasing it.
8. Mark the coupon as hot. Use the method established in Chapter 1 for identifying hot material.
9. Allow the bead to cool enough for safe cleaning. Do not chip or brush a bead that is still hot enough to burn through gloves.

J. Cleaning and Inspection

1. Remove slag using safety glasses, face protection, and controlled chipping. Direct chips away from bystanders and the fire-watch position.
2. Wire-brush the bead using the approved brush. Remove remaining oxide and loose material without contaminating the brush with other metal types.
3. Inspect arc-start quality, bead continuity, width, height, ripples, slag removal, undercut, overlap, porosity, and arc strikes. Compare the bead against Section D.
4. Compare results from multiple starts. Identify which starts were clean and which showed sticking, excessive spatter, or arc strikes.
5. Adjust only one variable at a time under instructor direction. Do not change amperage, electrode, and technique simultaneously.
6. Repeat until consistent starting and short-bead control is demonstrated. Continue practice repetitions until the acceptance standard is met on request, not by chance.
7. Record settings, observations, defects, corrections, and accepted practice results. Complete the practice-bead log for every recorded attempt.
8. Shut down the station and complete the fire-watch check. Follow the shutdown sequence in the Cleanup section below.