Best Stick Welder – DC Inverter Portable Arc Machine Reviews [110v & 220v] – 2024

Stick Welder Buyer’s Guide

To better understand how to choose a stick welder or the best portable welder in your bight range here are some things that you need to consider and have to be aware of. It is going to help you when buying either a small stick welder or any kind that you need.

Basic Features to Pay Attention to on Every IGBT Inverter Stick Welder

There are certain things that not a lot of people will tell you about when it comes to setting, maintaining, and generally using stick welders. Certain practices can be acquired with experience and usage. But there are some things that you still need to hear from someone.

We are not shy about divulging such information and there are a few things that you have to pay attention to.

Amperage Output Range

For making multi passes, more knowledge is required. A 150 amp stick welder can be a good choice as it provides good weld depth and can melt pretty much anything. Combine that with the skill of making multi passes and you are on your way to being capable of doing any kind of work that you have in mind.

However, the main thing to consider is still the amperage range. You should know how many amps you are going to use for a certain electrode. This is particularly important for working on thicker materials. Check the amperage range on the electrodes that you are going to be using. Each one of them has a recommended amperage that you will need to adjust your stick welders by.

The Duty Cycle

A duty cycle is the amount of time a welding machine can operate at a given output without exceeding its temperature limits. So, if a 285 amps/28 volts welder possesses a 40% duty cycle, it means that it can properly function for 4 minutes at 285 amps/28 volts after which it will need to cool down before you can come back at it again.

However, there are certain subfactors that welders need to consider.

The duty cycle and welding output are proportional. Therefore, when welding at lower outputs the duty cycle should increase. In that case, the machine mentioned above should increase its duty cycle to 60%. A duty cycle needs to be evaluated at a certain temperature. Most welders agree that the golden standard is 104o F. If the ambient temperature is lower the duty cycle will increase. Thus a machine welding at 70o F could potentially increase its duty cycle to 100%.

If you are using a multi-process welder with a multi-voltage system the welding outputs will change based on the process used and input power.

Material Thickness

With a stick welder, you can weld almost anything, even the thickest metals. It is meant for heavy-duty work so there isn’t even a maximum threshold that you have to worry about. However, you can’t go through a 1-inch plate in a single pass, it will most certainly require making more.

With a 120 amps welder, you can easily weld a 1-inch thick metal plate, in multiple passes, and with 140 amps one you can work on almost anything.

Inverter Stick Welder Useful Features to Look for

Let’s not forget some features that a welder comes with that you can use to your advantage.

Hot Start Feature

Hot start is a very useful feature that some welders simply can’t go without. Having a welding machine with a hot start can greatly improve your stick weld performance. It is a special feature for MMA where a peak current is created by the machine once the arc is struck.

This comes in handy if you are working in unlawful conditions by working outside as it allows you to start the electrodes without issues. Some problems that welders run into are damp electrodes or others that are difficult to run. You might be even working on an imperfect job surface.

All of that can be avoided if your machine has a hot start function, so you can just run it and you are good to go. It works best with the basic 7018 electrodes.

Arc Control or Arc Force Feature

In MIG, arc control allows you to set the inductance and slope. While in Pulse or Accu-Pulse mode, this feature can change the arc characteristics which you can do by preprogramming the factory pulse data. However, tinkering with the factory settings should only be done if you are having major issues with the program that you are using and is not something a beginner should do.

Anti-Stick

The anti-stick does exactly what the name suggests – prevents the electrode from sticking. There are a number of situations when this could happen and it even occurs to experienced welders. Having an anti-stick mode on your side allows you to detach the welding electrode if it starts to stick to the workpiece.

What the machine does is collapsing the welding current once it senses that the electrode is sticking. The electrode will not continue to weld itself to the workpiece and you can break it free easily.

The anti-stick function is something that you should consider using and will help you not to waste so many electrodes.

Multi-Process Machines

A multi-process machine is a great tool to have in your welding arsenal. The biggest advantage of these kinds of machines is that they work as a swiss-army knife. You can use it for different types of welding without having to unplug and set an entirely different machine up. Even professional welders have these types of machines in their garage, just in case.

A single MIG/TIG/Stick multi-function machine allows you to weld in three different styles with a flick of a button. But there are downsides to it, as cheaper machines don’t really perform every individual process properly. If you want a really good one, you should invest more money and buy a bigger one.

However, we still recommend getting one. Even cheaper versions are enough for smaller jobs around the house. Plus, a beginner can use this type of machine and start learning some welding processes without having to invest in a single expensive machine.

TIG Capability – Scratch Start vs Lift Start vs High-Frequency Start

It is the most basic and rudimentary method, but still effective, and is used on the cheapest kinds of inverters.

Lift start TIG ignition involves touching the workpiece with the tungsten electrode and lifting it away. The starting current is not too high so the electrode is not in any danger of sticking to the work. Once the machine senses that the contact is broken, it will start supplying a full welding current.

Finally, High-Frequency TIG ignition is the most advanced and simple one to use as you only need to position the tungsten electrode near your work and press the trigger to ignite the arc.

Comparing all three of them, the scratch start is the least expensive one. However, it is the least effective one as well. If you happen to find a machine with either lift start or HF start, don’t miss the opportunity to get one. HF start is particularly good to have and you can usually find it on professional welders.

Budget

People who are simply looking for a welder to help them with occasional work around the house or simple DIY projects are not going to look to spend large amounts of money on a 115-volt welder.

So unless welding is your source of income, you should look at some stick welding machines that do not cost so much but are still able to offer you what you need for occasional work. For those people, stick welders from YesWelders are perfect. They are the least expensive ones on the market but at the same time are capable of providing you with good, quality results. They are also quite superior to the other welder in the same price range.

But if you are ready to spend more cash you should look for stick welders from brands from a manufacturer like Hobart or Lincoln Electric. You should also be aware of the fact the stick welding machines that cost more money also come with a longer warranty as well and may even last for life.

What Type of Projects are you Planning?

You should consider the type of stick welder you need based on your future plans. For example, if your intention is to do some basic work or run a small welder’s workshop, you are not going to need all those big and strong machines.

However, even for that type of work, a medium-grade machine works best. The smaller 110v ones should only be used out of necessity. You can’t do a lot with them.

Pen to paper and determine the workload and projects that you are planning to work on. That way you can determine the best type of machine that you need to get.

Advantages

Stick welders hold a number of advantages compared to other machines. They can basically do it all. You can work outside and in different weather conditions, not even hampered by the breeze. You can weld in various positions and work on various projects.

Pipe welding and other similar kinds of jobs can be done with a stick welder, the only thing that matters is the power.

Basically, this is the most inexpensive welding method which also does not require expensive equipment. Stick welders themselves are also far less expensive than other types of welding machines.

Disadvantages

Unfortunately, even the best stick welders have their downsides.

You can’t weld fast with it as it is generally one of the slower welding processes. It also takes more to master as opposed to other types of welding. You can’t be a beginner and start welding off the bat, it takes some time to really get good and learn all the ins and outs.

Also, it is not a process that can be used for welding thinner materials.

Should you Use a Stick Welder for Auto Repair?

In theory, one can use a stick welder for an auto repair, but it is not recommended. Stick is not really good when working on thinner metals and may cause burn through. Using stick for auto repairs will require substantial skill and experience which not a lot of people have.

Being that auto parts are very thin, the most appropriate method to use is MIG. So if you are planning to repair some auto parts, don’t waste your time trying to do it with a stick welder. You will just end up losing valuable time.

Input Voltage and Household Current [220v or 110v]

A stick welder can come with both 110v and 220v welding power supply and can perform at both settings well. However, switching to 110v from 220v means working with half the power.

The advantage of using a 220v household circuit lies in having much more available amperage. You can also use larger diameter rods and weld thicker materials. It also has a larger duty cycle as opposed to the range where the 110v one tops out at.

If you run your welder on at or below the maximum output of your 110v welder you’ll see no difference, with perhaps the only one being the diminished duty cycle time for the 110v welder.

At 220v, you get more concentrated heat and more penetration.

Accessories and Consumables

Let’s not forget about the accessories and consumables that can sometimes prove to be much more valuable than they seem.

Cable Length and Thickness

A welding cable is used to supply the electric arc welder with power. These types of cables are meant to be both durable and flexible. A welder will constantly need to move around a workshop so you better have a cable that is both long enough and thick enough for the work you are doing.

A weaker cable can easily get damaged due to abrasions, cuts, burns from sparks, and oil and water exposure. When you buy a new machine, they don’t tend to supply you with the most quality cables. So it is a good practice to make a trip to the hardware store and get a more quality one. The weaker ones are subject to wear and tear and you are not going to want that while welding.

Things to consider when getting a suitable cable are ampacity, gauge, length, insulation, flexibility, and color. You might think that the color doesn’t make a whole lot of difference, but it helps to distinguish cables from one another if you have more of them.

Ground Clamp

Grounding is a necessary safety practice when working with electrical equipment, in this case, an arc welder that may consist of several electrical circuits. Grounding is usually made with the help of a ground clamp. The best ones available are those made entirely of copper as it is the best conductor of electricity.

There are several ground clamps, even magnet ones, but choosing which one to use entirely depends on the work you are planning to do. The most important thing is that the ground clamp is made out of solid material and that you are able to tightly fasten it to the workpiece.

It is very important that the area where the ground clamp is connected is wiped off and cleaned thoroughly. You don’t want dust or slag hampering the connection. Also, if the material originally has paint, be sure to brush the paint off to establish a better connection.

If you notice your ground clamp heating up, it may mean that it is faulty. You should definitely replace it as it could potentially start a fire.

Electrode Holder

An electrode holder, also called a stinger, is a device that a welder uses to clamp down an electrode and securely and safely hold it while working in any position.

However, you can’t have just any old piece of equipment here, you have to get one made of solid material, copper works best, that can clamp the electrodes properly. The electrode should fit tightly inside and should not be able to move around. If the electrode is loose it can cause a short-circuit.

So our advice is to not be stingy with something that doesn’t seem all that important but can create bigger problems at some point.

Basic Stick Welding Electrode Selection

The best practice is to pick an electrode that matches the strength properties and the composition of the metal you are about to work on. Next is matching the electrode type to the welding position and the used power source. Some electrodes are only meant for either DC or AC usage, but there are some that are meant for both.

Assess the joint design and choose the electrodes that allow for the best penetration. You should also consider electrodes with maximum ductility to avoid cracking on thick materials. Finally, one should also have production efficiency in mind. Using electrodes with high iron powder content (E7014 or E7024) will offer a suitable deposition rate.

Learning to Weld on a Stick Welder

Stick welding remains the most difficult welding process to learn and that is why you should learn it first

Good preparation and extensive practice are what will help you get the skill level for proper stick welding. Learning how to weld some basic stuff and small repairs will require around 5 hours of practice. It is not going to be pretty and the welds might seem rough, but if you are not looking to make a career out of it, this should be enough.

However, if you are aiming at an entry-level, about 500 hours of practice is needed while intermediate requires 900 hours. Making it all the way to the top requires 1,200 hours of practice and additional training that might last between 18 months to 2 years.

There are some courses that you can apply for and also find certain schools. But it is going to be hard to start doing it by yourself. You are more than likely going to need some professional help.

Inverter or Transformer

Picking between them depends on your project. Inverter welder is more flexible and allows you to switch from one process to the other with ease. They can also be carried around a site as they are a lot lighter.

Transformers are famous for their durability and can be used in various working conditions. It doesn’t matter if you use them outside or inside. They do pack a bigger punch and can help when working on thicker metals, but you will need more experience to work with them. A novice is not going to be able to learn how to use it that quickly.

These days most of the main brands don’t even consider building transformer machines. The inverter efficiency, its features like overheating and overload protection, light weight, and the ability to weld everything from stainless steel to nickel and brass outway all the benefits of transformer welders.

Should You Buy a Used Stick Welder

It might seem that a used stick welder sounds like a better option but you should consider the risks involved. For instance, it simply may not be able to perform the way you imagine it would. This goes particularly well with the 220v/110v ones.

If you are going for a smaller and cheaper option, you should get a new one. They already come with a warranty and are generally not going to cost you a fortune. But if you have an opportunity to get a used industrial stick welder, you better jump at it. Those machines, even though they are used, can last a lifetime as they are build to last and are high-quality.

Safety

When it comes to safety, there are some standard safety procedures that you have to follow when it comes to arc welding. However, stick welding does create more spatter and a lot of sparks can flay around while you work. This is why you have to take some special precautions.

A welding helmet is a must. The mask will protect both your eyes and face from sparks and spatter. The same goes for your hands and arms. Wearing heavy leather gloves, an apron, and body protection with long sleeves is also necessary. You should button the sleeves up and the collar as well to prevent hot chunks from getting inside.

Finally, ventilation is equally important as with any other welding process. However, with stick welding process, some electrodes might give off dangerous fumes. It helps that most of the stick welding is done outside so the only thing that you have to think about is not holding your head directly above the fumes. But if you are working inside, a proper ventilation fan is needed. Opening a door or a window is basic but you should install an advanced fume extracting system. Also, pay close attention before starting to weld on a possible faulty circuit breaker or damaged power or welding cables.