Stick Welding Square Tubing – Your Friendly Guide

Stick welding square tubing is a popular welding process used to join metal tubes of equal dimensions. It is an art that requires skill, proper technique, and knowledge of the equipment and safety protocols. Whether you are a seasoned welder or just starting, mastering this welding technique will allow you to create strong and aesthetically pleasing welds. In this comprehensive guide, we will walk you through the process of welding square tubing using the stick welding technique.

Stick Welding Square Tubing
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Stick Welding Process

Before diving into welding square tubing, it’s essential to have a strong understanding of the stick welding process. Stick welding (also known as shielded metal arc welding or SMAW) is an arc welding process that uses a consumable electrode covered in flux to lay the weld. The flux coating melts when heated, creating a shield that protects the molten metal from oxidation and other atmospheric contaminants.

When beginning a stick welding project, there are a few key pieces of equipment you will need:

Welding machineThe welding machine provides the electrical current to strike and maintain the arc.
Electrode holderThe electrode holder clamps the electrode in place and conducts the electrical current to the electrode.
Ground clampThe ground clamp provides a path for the electrical current to return to the welding machine.
Consumable electrodesThe consumable electrode is the metal rod that is melted to create the weld. Different electrodes are used for different materials and applications.
Personal protective equipment (PPE)Welding PPE includes gloves, a helmet with filter lenses, a respirator, and clothing that covers the skin to protect the welder from the heat, light, and fumes produced during welding.

The stick welding process itself involves striking an arc between the electrode and the base metal, creating heat that melts the metal and the electrode. As the electrode melts, it forms a pool of molten metal that fuses with the base metal to create the weld.

It’s important to maintain the correct arc length (the distance between the electrode and the base metal) to prevent the electrode from sticking to the metal or the arc from extinguishing. Too short of a distance can cause the electrode to melt too quickly and create a poor-quality weld, while too long of a distance can result in an unstable arc that produces a weak weld.

Now that we have covered the basics of the stick welding process and the necessary equipment, we can move on to exploring specific techniques for welding square tubing.

Stick Welding Techniques for Square Tubing

Welding square tubing requires specific techniques to achieve the desired results. Here are some of the most effective stick welding techniques for welding square tubing:

Joint Preparation

Preparing joints is a crucial step in stick welding square tubing. Square tubing is often used in structures, which means the joints will be subjected to varying stresses and forces. It’s essential to prepare the joints thoroughly before welding. Start by cleaning the joint surfaces, removing all dirt, debris, and rust using a wire brush or grinder. After cleaning, ensure the joint is tight-fitting, with a minimal gap between the two pieces of tubing. A tight-fitting joint will ensure efficient heat transfer and optimal penetration.

Bead Placement

The placement of the weld bead plays a significant role in the strength and appearance of the weld. Begin by striking an arc at the starting point and moving the electrode along the joint in a straight line. Keep the electrode close to the joint and aim for a consistent weld bead size. For square tubing, avoid weaving the electrode as you weld, as this can create a weak and less appealing weld. Instead, maintain a steady and even travel speed while welding.

Electrode Angle

Electrode angle refers to the angle between the electrode and the joint. The electrode should be held at a 90-degree angle to the joint, and the electrode’s tip should be pointed towards the direction of welding. This angle ensures the electrode’s full coverage of the joint and helps prevent undercutting, where the weld penetrates too deeply, creating a weakened joint.

Travel Speed

The travel speed refers to the speed at which you move the electrode along the joint. Maintaining a consistent travel speed is crucial for a uniform and aesthetically pleasing weld. Generally, a slower travel speed is required for thicker materials and larger tubing. Ensure that you don’t move too slowly, as this can cause excess heat buildup, leading to burn-through.


The amperage level will depend on the thickness of the tubing and the electrode size. Generally, a lower amperage is required for thinner tubing, while thicker tubing requires a higher amperage. It’s essential to strike a balance between amperage and travel speed to avoid over-welding or under-welding the joint.

By using these stick welding techniques, you should be able to achieve strong and visually appealing welds on square tubing. Ensure that you practice these techniques regularly to improve your skill, and don’t hesitate to experiment with different techniques to find what works best for your specific project.

Tips for Stick Welding Square Tubing

Stick welding square tubing may seem like a daunting task, but with these expert tips, you will be able to achieve perfect welds in no time.

Tip 1: Proper joint preparation is key to producing strong and durable welds on square tubing. Be sure to clean the joint thoroughly and remove any rust or debris before beginning the welding process.

Tip 2: Maintaining proper arc length is essential for achieving optimal penetration. Keep the electrode at the correct distance from the base metal and adjust as needed throughout the welding process.

Tip 3: Controlling heat input is crucial to producing aesthetically pleasing welds. Monitor the arc and adjust the amperage as needed to prevent overheating or underheating of the metal.

Tip 4: Achieving a consistent bead placement is key to producing a professional-looking weld. Control the size and shape of the bead by adjusting your travel speed and electrode angle.

Tip 5: Practice makes perfect. Don’t be afraid to experiment with different techniques and settings to find what works best for you. With time and practice, you’ll be able to master the art of stick welding square tubing.

Ensuring Safety in Stick Welding Square Tubing

When it comes to stick welding square tubing, safety should always be a top priority. Welding produces intense heat and bright light, which can pose significant hazards if not handled properly. Here are some essential safety tips to follow:

  • Wear protective gear: Proper personal protective equipment (PPE) is a must when welding. Ensure you have a welding helmet, protective glasses, gloves, and clothing made of flame-resistant material.
  • Keep your workspace organized: Cluttered workspaces are more prone to accidents. Organize your workspace to prevent tripping hazards and to have easy accessibility to your equipment.
  • Ensure proper ventilation: Welding produces fumes that can be hazardous to your health. Ensure your workspace is well-ventilated to reduce exposure to fumes.
  • Inspect your equipment: Regularly inspect your welding equipment to ensure it’s in good working condition. Replace any damaged or worn-out parts immediately to avoid accidents.
  • Be aware of your surroundings: Make sure there are no flammable materials near your workspace, and be aware of your surroundings to prevent accidents.

By following these safety tips, you can ensure a safe and secure welding environment. Remember, safety should always come first, and it’s better to be safe than sorry.


You are now equipped with the knowledge and techniques necessary for mastering stick welding square tubing. By following the expert tips, practical advice, and easy-to-follow instructions in this comprehensive guide, you can achieve perfect welds on square tubing.

Remember, welding square tubing requires specific techniques, and safety should always be a priority. Make sure to follow the essential safety precautions and practice diligently to unlock a world of possibilities with stick welding.

Whether you are working on a personal project or a professional endeavor, these insights will help you achieve strong and visually appealing welds on square tubing. Embrace the art of stick welding and start your welding journey today!


What is stick welding?

Stick welding, also known as shielded metal arc welding (SMAW), is a process that involves joining metals using an electrode (stick) coated in flux. The electrode produces an electric arc, which melts both the electrode and the base material, creating a weld.

Can I weld square tubing with stick welding?

Yes, stick welding can be used to weld square tubing. By following the appropriate techniques and tips, you can achieve strong and visually appealing welds on square tubing.

What equipment do I need for stick welding square tubing?

To successfully stick weld square tubing, you will need a welding machine capable of performing stick welding, welding electrodes (sticks), welding gloves, a welding helmet, welding clamps, and a chipping hammer, among other essential welding equipment.

What are some tips for stick welding square tubing?

Some key tips for stick welding square tubing are maintaining proper arc length, controlling heat input, using the appropriate welding technique, ensuring good joint fit-up, and cleaning the workpiece before welding.

How do I ensure safety while stick welding square tubing?

Safety is crucial when stick welding square tubing. It is essential to wear personal protective equipment (PPE) such as welding gloves, a welding helmet with appropriate lenses, long sleeves, and long pants. Additionally, ensure proper ventilation and work in a designated welding area.