Stick Welding Calculator
Choose your material and electrode to get a solid starting range. Always run a quick test weld.
Tip: Mild steel rods are the most common for home + shop work.
After choosing a material, this list will unlock.
Stick Welding Calculator & Amperage Settings Guide (SMAW)
Stick welding (SMAW) is often considered the most difficult process to master because it is less forgiving than MIG. The difference between a strong, penetrating weld and a glob of cold slag often comes down to one variable: Amperage.
Using our Stick Welding Calculator above, you can eliminate the guesswork. Whether you are burning a 6010 root pass or capping with a 7018, getting your settings right before you strike the arc is 90% of the battle.
- Rule of Thumb: For every 0.001 inch of electrode diameter, use 1 Amp. (e.g., 1/8" rod = 0.125" = ~125 Amps).
- Thickness Matters: Thicker metal acts as a heat sink, requiring higher amperage to maintain the puddle.
- Electrode Personality: 6010 rods like "whip and pause" techniques. 7018 rods prefer a steady drag.
- Polarity: Most structural stick welding is done on DCEP (Direct Current Electrode Positive) for maximum penetration.
How to Read Stick Welding Calculator Results
The calculator provides a "Range." Why not a single number? Because every machine and every welder is different.
1. The Amperage Range
If the calculator suggests 90 - 120 Amps, start at 105 Amps (the middle).
💥 Turn it up if: The electrode sticks to the metal or the arc keeps extinguishing.
💥 Turn it down if: You are burning through the metal or the electrode is glowing cherry red uncontrollably.
2. Polarity Selection
DCEP (Reverse Polarity): Delivers 70% of the heat to the rod and 30% to the work. This provides deep penetration and is the standard for 6010 and 7018 rods.
AC (Alternating Current): Used primarily on "Buzz Box" welders that don't have DC capability. Only use rods specifically designated for AC (like 6011 or 6013AC).
You May Want to Shop Stick Welders
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Reference Chart: Manual Amperage Settings
Prefer a static chart for your shop wall? Here are the standard operating ranges for the most common electrodes.
| Electrode | Diameter | Amperage Range | Application |
|---|---|---|---|
| 6010 / 6011 | 3/32" | 40 - 80 A | Root passes, Rusty metal |
| 6010 / 6011 | 1/8" | 75 - 125 A | Deep penetration, Pipe |
| 6013 | 1/8" | 80 - 130 A | Sheet metal, General repair (Low penetration) |
| 7018 | 3/32" | 70 - 100 A | Structural Steel, Heavy Plate |
| 7018 | 1/8" | 110 - 150 A | Structural Steel (Most Common) |
Troubleshooting: Why is my weld failing?
Even with the correct numbers from the stick welding calculator, technique is king. Here are common issues:
Sticking Rods
If your rod sticks immediately upon striking, your Amperage is too low or your Arc Start is too aggressive. Try scratching the rod like a match rather than tapping it.
Porosity (Wormholes)
This is usually caused by Long Arc Length. You should hold the rod roughly 1/8" away from the puddle. If you pull away too far, the shielding gas dissipates, and air ruins the weld.
✨ Read More About: What Is Porosity in Welding? Causes, Effects, and Prevention
Undercut
If the edges of your weld are dug out, your Amperage is too high or your Travel Speed is too fast. Slow down and let the puddle fill the toes of the weld.
✨ Read More About: What Is Undercut in Welding?