SMAW Welding: 22V / 180A
Heat input at travel speeds 100–300 mm/min (efficiency η=0.8)
SMAW at 22 V and 180 A is a workhorse parameter set used across structural fabrication, pipe welding, and general repair work on carbon and low-alloy steels. At this electrical input the arc transfers enough energy to fuse plate from about 3 mm up to roughly 12 mm in single-pass work, with thicker sections handled in multiple passes following a qualified WPS. The voltage value controls arc length and bead width while the current value governs deposition rate and penetration; together they define a stable operating envelope that experienced welders can read from puddle behavior alone. Always match the wire diameter and shielding gas to the parameter set called out in your Procedure Qualification Record.
SMAW (Shielded Metal Arc Welding), commonly called stick welding, uses a consumable coated electrode. The flux coating generates shielding gas and slag to protect the weld pool. Highly portable and versatile, SMAW is used in maintenance, repair, pipeline, and structural applications where access is limited.
At 22 V and 180 A, the electrical input power is 3960 W. Voltage primarily controls arc length and bead profile — higher voltage widens and flattens the bead — while current drives deposition rate and penetration depth. Exceeding the rated current for a given wire diameter increases the risk of burn-through on thin sections and premature contact-tip wear.
Heat input directly affects the weld metallurgy. Lower heat input preserves heat-sensitive alloys and reduces distortion; higher heat input improves fusion on thick sections but may coarsen grain structure and reduce toughness. Always verify that heat input falls within the Procedure Qualification Record (PQR) limits for the base material. For carbon steel, heat input above 3.5 kJ/mm may require post-weld heat treatment (PWHT) to restore toughness in the heat-affected zone (HAZ).
Welding Specification
| Process | SMAW |
| Voltage | 22 V |
| Current | 180 A |
| Process Efficiency | η = 0.8 |
Heat Input by Travel Speed
| Travel Speed (mm/min) | Heat Input Q (kJ/mm) |
|---|---|
| 100 | 1.901 |
| 150 | 1.267 |
| 200 | 0.95 |
| 250 | 0.76 |
| 300 | 0.634 |
Amperage Range Notes
Medium-amperage welding (150–249 A) is the general-purpose shop range that covers most structural fabrication on plate between 3 mm and 10 mm thick. This is the band where production GMAW with 0.035 inch / 0.9 mm wire and a 75/25 Ar/CO₂ mix dominates, where SMAW operators run 1/8 inch / 3.2 mm 7018 rods on column splices and bracket weldments, and where GTAW handles stainless and aluminum pipework with 1/8 inch tungsten. Multi-pass strategy starts to matter — split the joint into root, fill, and cap passes rather than trying to deposit the full cross-section in one bead.
Typical Use Cases
SMAW at 22 V / 180 A is suited to general-purpose carbon steel fabrication in the flat or horizontal position. Verify wire diameter and shielding gas composition against your weld procedure specification (WPS) before production runs.
Setup Checklist
Confirm wire feed speed matches the target current range. Set gas flow rate to 15–25 CFH for solid wire GMAW, or follow the flux manufacturer's instructions for FCAW. Inspect contact tips and liners for wear before welding. Preheat thick sections (> 25 mm) to reduce hydrogen cracking risk.