⚡ Stick Welding Calculator

SMAW amperage ranges, polarity, deposition rate, and optional rod estimates

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Welding Rod Chart

Both sizes - 8.5x11 and the 18x24 shop poster. $5.99.

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Welding

Welding Reference Card

One page. MIG, TIG, stick and flux core settings by thickness.

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Complete Welding Settings Guide

19 pages. Four processes, stainless and aluminum, symbols and inspection.

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Welding Job Estimator

Price the job, then hand over a quote with no internal numbers.

Excel or Google Sheets. Best on a computer.

$29.00

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Welding Complete Bundle

Card, 19-page guide and the estimator workbook. All six files.

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⚡ Recommended Stick Welding Equipment

Five picks for electrodes, torch accessories, PPE, and machines matched to SMAW workflow

Popular

Yeswelder 7018 Electrode Pack

Low-hydrogen 7018 for smooth welds
1/8" diameter — common structural size
Sealed packaging limits moisture pickup
Matches calculator 7018 workflows
Great everyday rod stock

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Tweco Professional Electrode Holder

High-amperage duty cycles
Grips 1/16" through 5/32" electrodes
Heavy-duty brass jaws
Comfortable grip for long beads
Core SMAW handpiece upgrade

View on Amazon →

PPE

ARCCAPTAIN auto-darkening welding helmet

ARCCAPTAIN Auto-Darkening Helmet

True-color lens clarity
Fast arc sensors — stick/MIG/TIG
Wide viewing area
Comfort headgear
Strong value under $100

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Best value PrimeWeld 3-in-1 welder with stick mode

PrimeWeld 3-in-1 Welder / Plasma

Stick + MIG + TIG capability
Portable inverter footprint
Ideal second machine for SMAW jobs
Plasma cutting when you need it
Pairs with calculator amp targets

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VASTOOLS welding accessories kit with hammer and brush

VASTOOLS 6-Piece Welding Kit

Chipping hammer & wire brush
Pliers, magnets, gloves basics
Shop essentials next to the stinger
Great add-on for field SMAW
Everything to dress slag & tack

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How to Use the Stick Welding Calculator

Select your electrode type and diameter, choose your welding position, enter your material type, and optionally add project details for rod consumption estimates. The calculator provides amperage ranges based on the proven formula of 40 amps per 1/32" of electrode diameter, adjusted for position and electrode type.

Electrode Diameter vs Amperage Range

SMAW amperage scales with electrode diameter (roughly 30–40 A per 1/32" of diameter), then shifts with position and coating. The calculator already applies position factors; use Advanced options to lock polarity preference, arc force / dig, and travel speed for heat input.

Fig. 1 — Typical flat-position amperage windows by electrode diameter. Vertical-up and overhead usually run 10–25% cooler; vertical-down even cooler.

Diameter	Flat amp window	Rule of thumb
1/16" (1.6 mm)	40–70 A	~40 A × 2/32"
3/32" (2.4 mm)	70–110 A	~40 A × 3/32"
1/8" (3.2 mm)	90–150 A	Most common structural size
5/32" (4.0 mm)	130–200 A	Heavier plate / fill passes
3/16" (4.8 mm)	160–250 A	High deposition flat work

Understanding Amperage Recommendations

The calculator gives you both a recommended range and an optimal setting. Start at the optimal setting and adjust based on your results. If the rod sticks constantly, increase amperage by 5-10 amps. If you're burning through, reduce amperage and increase travel speed. If the arc is erratic, check your ground connection first.

Electrode Types and Applications

E7018 (Low Hydrogen): The most popular electrode for structural welding. Produces smooth, strong welds with minimal spatter. Must be stored in a rod oven at 250-300°F to prevent moisture absorption. Use a drag technique and AC or DCEP polarity.

E6010 (Deep Penetration): King of all-position welding, especially for pipe and root passes. Works on rusty, painted, or dirty metal. DCEP only. Use a whipping motion for vertical-up.

E6011 (All-Position AC): The AC version of 6010 with similar characteristics. Great for farm and maintenance welding. Also works on DCEP.

E6013 (Easy Arc): Beginner-friendly with smooth, stable arc. Medium penetration and easy slag removal. Works on AC, DCEP, or DCEN.

E7024 (High Deposition): Flat and horizontal only. Very high deposition rate. Not suitable for vertical or overhead.

💡 Pro Tip: Arc length is critical for stick welding. Maintain an arc length equal to your electrode diameter. The rule "if you can hear it, you're too far" helps – a short arc is quiet and smooth, a long arc is loud and erratic.

Shopping for a stick welder? Check our stick welder reviews to find the right machine for your needs, from lightweight portable units to industrial powerhouses.

When Stick Still Fails — Diagnose the Arc

Rod sticking, spatter/arc blow, 7018 porosity, undercut, or burn-through vs lack of fusion: Stick Welding Rod Troubleshooting. Rod family choice (6011 vs 6013 vs 7018) stays on the Stick Rod Chart & Selection Guide. Process choice (why Stick at all): MIG vs TIG vs Stick.

⚡ Stick Welding Calculator

Welding Rod Chart

Welding

Welding Reference Card

Complete Welding Settings Guide

Welding Job Estimator

Welding Complete Bundle

⚡ Recommended Stick Welding Equipment

Yeswelder 7018 Electrode Pack

Tweco Professional Electrode Holder

ARCCAPTAIN Auto-Darkening Helmet

PrimeWeld 3-in-1 Welder / Plasma

VASTOOLS 6-Piece Welding Kit

How to Use the Stick Welding Calculator

Electrode Diameter vs Amperage Range

Understanding Amperage Recommendations

Electrode Types and Applications

When Stick Still Fails — Diagnose the Arc

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