Using a welder as a cutting tool is not something most welders plan to do but it’s a technique that has existed for decades. When you don’t have access to a plasma cutter, oxy-fuel torch, or angle grinder, a welder can be pressed into service to cut metal in a pinch.
The result is functional but far from pretty, and it should always be treated as a rough or emergency fabrication method, not a precision process.
That said, when done correctly and safely, it can absolutely work.
What’s Really Happening When You “Cut” With a Welder
Unlike plasma or oxy-fuel cutting, a welder does not rely on a focused jet of ionized gas or a chemical oxidation reaction. Instead, the cut is produced by extreme localized heat that melts the base metal and physically pushes it out of the kerf.
Because molten metal is being forcibly displaced rather than cleanly sliced, the cut will always have slag, rough edges, and some distortion. This is normal and unavoidable with this technique.
Shielded Metal Arc Cutting (SMAC): The Most Common Method
The most widely used method for cutting with a conventional welder is Shielded Metal Arc Cutting, often abbreviated as SMAC. This is done with a standard stick (SMAW) machine and relies on electrode selection, amperage, and technique rather than machine specialization.
Electrode Choice Matters
Not all electrodes behave the same when used for cutting. Rods such as 6011 and 6013 are commonly preferred because their flux composition creates a more aggressive, forceful arc. This helps blow molten metal out of the cut path instead of letting it resolidify in place.
Low-hydrogen rods like 7018 are poor choices for cutting. They tend to produce a softer arc that struggles to clear material efficiently.
Amperage Settings for Cutting
Cutting requires significantly more heat than welding. As a result, amperage settings need to be increased well beyond normal welding values.
For thinner material, settings in the 125-135 amp range may be sufficient. For heavier plate, some operators run anywhere from 175 up to 225 amps, depending on machine capability and electrode diameter.
Higher amperage increases cutting speed but also increases spatter, slag, and heat-affected zones, so balance is important.
Cutting Technique
Once the arc is initiated, the electrode is pushed directly into the metal rather than dragged along a joint like a weld. The motion is often described as a poking, stabbing, or sawing action, where the goal is to burn through the full thickness and continuously clear the molten metal.
Maintaining a consistent arc while advancing through the material is the biggest challenge. Too slow, and the metal closes behind the rod. Too fast, and the arc extinguishes or leaves uncut sections behind.
This technique takes practice, but it’s surprisingly effective once mastered.
The “Soaked Rod” Trick And Why Caution Is Required
Some welders briefly dip their electrode in water before cutting. The moisture flashes into steam when the arc is struck, helping to eject molten metal from the cut path.
While this can make cutting easier, it also introduces steam explosions, erratic arc behavior, and excessive spatter. This method is messy and potentially dangerous if used carelessly. It should only be attempted with full protective gear and a clear understanding of the risks.
Expect Cleanup
Cuts made with a stick welder will not be clean. Slag buildup, jagged edges, and uneven kerfs are part of the process. An angle grinder is almost always required afterward to smooth and dress the edge to an acceptable finish.
If you need tight tolerances or visible edges, this method is not ideal.
Using Laser Welders With Cutting Functions
Modern multi-function laser welding machines often include a dedicated cutting mode. These are typically marketed as 3-in-1 or 4-in-1 units and are designed from the ground up to handle cutting tasks.
In cutting mode, the welding nozzle is replaced with a cutting nozzle, the beam is focused to a single point, and the machine runs at maximum peak power. Oxygen is typically used for fast carbon steel cutting, while nitrogen is preferred for stainless steel and aluminum to produce cleaner edges.
This process delivers vastly better results than stick cutting but is dependent on specialized—and expensive equipment.
Multi-Process Welders With Plasma Capability
Some multi-process machines include an integrated plasma cutting function. In this case, the welder is not being “repurposed” as a cutter the machine is simply switching roles.
Using plasma cutting requires changing leads, attaching a plasma torch, and connecting a compressed air supply. While this setup offers clean, fast cuts, it’s only available on specific models designed for the task.
Safety Considerations You Should Not Ignore
Cutting with a welder produces violent sparks, molten metal spray, and intense arc radiation. The risk profile is higher than normal welding because metal is being forcibly expelled from the cut.
Eye protection is critical. A welding helmet set to shade 11 or 12 is typically recommended due to the sustained high-intensity arc. Skin protection, fire-resistant clothing, and gloves are mandatory.
Fumes are also a concern, especially when cutting painted or coated steel. Always work in a well-ventilated area and use a respirator when appropriate.
Final Thoughts
Yes, you can use a welder as a cutter but it’s best viewed as a problem-solving skill, not a replacement for proper cutting tools. Stick cutting is loud, dirty, and imprecise, but it can get you out of trouble when nothing else is available.
For rough fabrication, demolition, or emergency work, it’s a valuable technique to understand. For clean results, speed, and accuracy, dedicated cutting tools will always win.
Knowing both is what makes a versatile fabricator.