FCAW vs Stick Welding: In-Depth Comparison, Pros & Cons and Applications

Table of Contents > 1. Arc Welding Methods In Everyday Welding     1.1 Brief Overview Of Stick Welding       1.1.1 Pros And Cons of Stick Welding     1.2 Brief Overview Of Flux-cored Welding       1.2.1 Pros and Cons Of Flux-core Welding     1.3 Similarity Between Flux Core And Stick Welding 2. FCAW Vs Stick Welding - Key Differences     2.1 Electrode Differences     2.2 Welding Deposition and Speeds     2.3 Welding Penetration And Heat Control     2.4 Equipment Costs     2.5 Weldable Materials     2.6 Skill Requirements and Ease Of Use 3. Which One is Better, Flux Core or Stick Welding? 4. 🧐FCAW vs Stick Welding: In-Depth Comparison, Pros & Cons and Applications FAQ

Flux-cored Arc welding and Shielded Metal Arc Welding are popular and versatile welding methods. Welders know them for working without an external shielding gas, which gives them the name slag welding processes.

While fundamentally the same, FCAW and SMAW show different welding results and performance. So, many are wondering what the differences between Flux-core and Stick welding are and which one is better.

There is no simple answer or clear winner. That's why we'll present an in-depth comparison of FCAW vs Stick welding, explaining the advantages and drawbacks in various applications.

FCAW vs Stick Welding
Photo by @datboimiggz (TikTok)

Arc Welding Methods In Everyday Welding

People often think about arc welding methods when discussing everyday welding, including home applications, DIY, or hobby projects. These methods, including Stick welding or Flux-cored arc welding, use the heat of an electric arc to melt and fuse the pieces.

There are dozens of arc welding methods, and some can be grouped based on their fundamentals. For example, we distinguish wire welding processes (MIG and Flux core), manual or semi-automated, or slag welding processes.

Flux core and Stick welding are known as slag welding processes. Both use self-shielded electrodes that contain protective flux. As the flux melts, it creates a slag layer, that protects the weld from atmospheric contaminations. As a result, you don't need an external shielding gas, allowing you to weld outdoors or in on-jobsite applications.

To further understand the differences between Stick and Flux-cored welding, you first must get familiar with their fundamentals. Let's briefly explain each.

Brief Overview Of Stick Welding

Stick welding or Shielded Metal Arc Welding (SMAW) is one of the oldest methods, patented at the end of the 19th century. The fundamentals of using an electric arc formed between an electrode was known as the first-ever welding method, but the process we know today was yet to be perfected.

Modern Stick welding also uses an electric arc to melt and fuse the pieces. The arc forms between a non-consumable electrode plugged into one side of the terminal and base metal connected to the ground on the other side of the terminal.

At its core, Stick welding is a relatively simple and cheap welding method. But what makes it unique are its self-shielded electrodes. These electrodes have flux around the core of the wire. As the flux melts during the welding, it creates a protective layer of slag that protects the molten metal from atmospheric contamination.

This principle means you don't need an external shielding gas, which cuts the overall costs. In addition, it allows you to weld outdoors without the risk of contamination. Low expenses, the ability to weld various metals, including steel, stainless steel, or even aluminum, and versatility make Stick welding one of the industry's favorites. However, it is not without drawbacks.

To learn more about SMAW, check out our article on How to Stick Weld.

Pros And Cons of Stick Welding

Advantages:

• Highly versatile: You can use it to weld steel, stainless steel, cast iron, or even aluminum. You can use it to weld outdoors or in harsh environments.
• High penetration: Stick produces deep penetrating welds, ideal for thick pieces.
• Portable: New stick welding equipment is lightweight and compact. You can carry your welder anywhere, even on a ladder.
• Low costs: Stick welders are relatively simple machines, and are usually cheap. You don't need to spend a fortune on gas, welder, and consumables.
• Excellent in various applications: The Stick welding's versatility makes it useful in various applications, from industrial pipelines and structural steel construction to home and hobby projects.

Drawbacks:

• Fumes and spatter: Burning the electrodes with flux creates fumes and excessive spatter. Hard spatter requires more post-weld cleaning.
• Not for thinner pieces: High penetration can cause burn-through or distortion on thinner pieces.
• Lower deposition rates: Stick welding is not the fastest welding method, as it takes time to fill the joint. It also includes periodic electrode change, reducing the overall productivity.

Brief Overview Of Flux-cored Welding

Flux-cored Arc Welding, or FCAW, is a newer welding method. It combines the self-shielded technique of Stick welding with the ease of use and speed of MIG welding, yielding a fast and versatile process.

In Flux-cored welding the arc forms between a self-shielded, flux-cored wire and base metal. Like the Stick electrode, flux-cored wire uses a flux to protect the molten puddle from contamination. However, flux-cored wire is longer, stored in spools, and hollow. The flux is placed in the hollow core of the wire, unlike the outer coating in Stick electrodes.

What Is Flux Core Wire?
Source: https://welditmyself.com/what-is-flux-core-wire/

Flux core welding is a semi-automated or fully automated process. Like MIG welding, flux-cored wire is automatically fed by the welder's wire feeding system into the welding gun through drive rolls and liner. 

Wire feed speed parameter (amperage) controls the feeding rate, and the process itself is much faster than Stick welding. Besides shielding the puddle, the flux inside the wire also controls the feeding rates of deposition, stabilizes the arc, and improves weld strength and consistency. 

While not mandatory, you can also add shielding gas to get even higher depositions and speed. Using two shielding sources creates dual-shielded welding, known for its depositions and speed in large-scale industrial applications.

 

Pros and Cons Of Flux-core Welding

Advantages:

• High deposition rates: Flux core welding provides high deposition making it ideal for applications where speed is paramount.
• Semi-automated process: The welder automatically feeds the wire at predetermined rates. The process can also be fully automated to produce fast, repetitive welds.
• Less downtime: Flux core wires come in large spools, reducing the need for frequent change.
• Better heat control: While also known for its penetration, Flux core welding provides better heat control at lower amps than Stick.
• Low electrode waste: You can use almost the entire length of the wire. There is no unused end waste of Stick electrodes.

Drawbacks:

• Toxic fumes: Burning flux creates fumes that can be harmful when working in cramped, enclosed spaces without proper ventilation.
• Higher costs: Flux core welding equipment is more expensive than Stick. The wire also costs more than electrodes, with increased expenses if you use dual-shielding.
• Not suitable for all metals: Welders typically use Flux core welding for steel.

Similarity Between Flux Core And Stick Welding

As noted, Flux-cored Arc Welding and Stick/Arc Welding share the same foundation. Nevertheless, there are more similarities between them, the most notable being:

• Both Stick and FCAW are arc welding methods.
• Both processes cannot be autogenous (welding without filler metal).
• Both methods use flux to protect the weld from contamination without external shielding.
• A protective slag layer forms in both processes, and you must remove it before further welding.

Remove the Slag after Stick Welding
Photo by @weldd1 (TikTok)

• Both processes use consumable electrodes. The electrodes are consumed during welding, and you eventually must replace them.
• Both are fusion welding methods, meaning the faying surfaces of the parent components melt and fuse.
• These methods produce fumes and spatter, posing hazards in the workshop.

Fumes and Spatter during FCAW Welding
Source: https://www.youtube.com/watch?v=6Rb6KclG4rQ

FCAW Vs Stick Welding - Key Differences

Although FCAW and Stick welding have much in common, they show different results in specific applications. To understand these differences, we'll need to look for critical factors, including the following:

• Electrode overview
• Welding speed and deposition rates
• Welding Penetration
• Equipment Costs
• Skill requirements
• Heat Control 

By understanding each factor, you can see which process is more suitable for your home projects. Here are the vital differences between Stick and Flux core welding summed up.

Stick (Shielded Metal Arc) Welding	Flux-cored Arc Welding
It uses short electrodes that require frequent change.	Uses a long wire electrode stored in spools.
Flux-coated electrodes.	Flux is located inside the hollow core of the wire.
Manual method.	Semi-automated or automated method.
Moderate to low speed and deposition.	High welding speed and depositions which can even be improved with dual shielding.
Can weld a wider variety of metals.	Mostly limited to steel welding.
Causes less fumes.	Creates excessive fumes.
Creates excessive and sometimes hard spatter.	It creates a limited amount of spatter.
Simple and cheap equipment.	Costly and more complex equipment and consumables.
Requires more skill to master.	Easy to learn and weld.
Risks of slag inclusion after changing the electrode.	Lower risks due to less frequent electrode change.
High penetration and lower heat control options.	Heat is easier to control.

Let's further explain each key difference between Stick and Flux core welding.

 FCAW vs. Stick Welding

Electrode Differences

Stick/Arc and Flux Core welding use consumable, self-shielded electrodes that melt and consume during the welding. However, the key difference between these processes is the form and structure of the electrode.

Stick welding uses traditional electrodes or rods that many are familiar with. The core of the electrode has a similar composition to the base metal you are welding, and the core is protected by flux. As a result, Stick electrodes are flux-coated. While producing less fumes, the coating is prone to moisture contamination, so you should carefully store them.

Meanwhile, Flux core electrodes such as YesWelder ET71-GS come in the form of a wire that is stored in spools. These wires are hollow, and the core is filled with flux, ergo the name flux-cored wire. The fillers also come in different diameters but are much longer than Stick electrodes. The flux in the core is much more resistant to moisture, but it can create more fumes.

 

 

While both electrode types are sold per pound, the difference in length can significantly affect work productivity. Stick electrodes usually come in 18-36” lengths. Once you burn through it, you must stop and replace it, creating a downtime during operation.

Flux-core wires come in large spools, and the welder feeds them automatically. Unless you change the diameter, you can weld with a single spool much longer than with Stick welding. Additionally, stick electrodes have unused ends you are clamping into the holder, so there is more waste during the operation.

Stick Welding Process
Photo by @adrianaortiz941 (TikTok) 

Welding Deposition and Speeds

A deposition rate represents the weight of filler (in pounds or kgs) deposited in the unit of time (per hour or minute). While the deposition can vary from the specific welding parameters and conditions, FCAW typically provides 3-5 times higher deposition than Stick welding.

This is a crucial factor when trying to cut overall welding costs. The ability to deposit much more filler metal into the joint also affects the operation speed, making FCAW faster than Stick.

In large-scale industrial applications where each buck matters, welders also use dual-shield Flux core welding. The dual shield wire is filled with flux and protected by external shielding gas.

Dual-shielding provides even higher speeds and deposition rates. So even though the initial costs of running a gas with self-shielded wire are higher, the increased productivity, deposition, and speeds cut down the overall welding costs.

Welding Penetration And Heat Control

Many welders favor Stick welding when welding thick stock due to its penetration. Stick welding produces deep penetration and high heat, eliminating the risk of lack of fusion and penetration and poor tie-in in thick pieces.

Flux core welding also produces good penetration suitable for thicker pieces. But at the same amperage, Stick provides more heat and runs deeper. One of the reasons is that flux-core wires are thinner than electrodes, but also the very foundation of the process.

While advantageous in most demanding applications, deep penetration is unfavorable when welding thinner pieces. Stick welding can easily burn through or distort thin pieces, so you should be careful.

With its limited heat and better control, the Flux core is more forgiving on thinner pieces. Nonetheless, both are not known for their performance on thin sheet metal, so you should consider MIG or TIG welding.

Equipment Costs

As noted, Stick welders, such as YesWelder ARC205 DS Pro are relatively simple, inexpensive, compact, and lightweight. You can easily carry them around the workshop or garage. Additionally, you don't have complex pieces such as liners, feeding mechanisms, torch accessories, and consumables, so Stick is often a go-to method when looking to complete the job cheaply.

ARC-205DS-PRO Digital Display 110V/220V Stick& Lift TIG In One Stick Welder

Flux core welders are often a part of more complex MIG welding machines. A single welder can run both processes, but the all-around expenses are higher. The flux-cored wire alone is more expensive than electrodes, and you should also consider a contact tip, nozzle, liner, and other consumable parts of the system.

Weldable Materials

Theoretically, you can Stick weld various metals, such as mild steel, carbon steel, cast iron, or even aluminum and nickel alloys. There are AWS-certified electrodes for these processes, so the initial versatility of Stick is much higher than FCAW.

In everyday welding, most welders use FCAW and SMAW to weld steel. Slag welding processes do not produce the cleanest welds like TIG welding, so you shouldn't expect excellent welding performance on aluminum or non-ferrous metals. That's why welders normally use both processes to weld various steel grades.

Skill Requirements and Ease Of Use

Stick welding is a manual welding method, often called Manual Metal Arc (MMA) welding. You only set the amperage and manually control other parameters such as arc length, feeding, travel speed, travel angle, etc. Manual fundamentals make Stick welding more challenging to master, as you'll need a steady hand and precise electrode manipulation.

Meanwhile, Flux core welding is a semi-automated process, that can easily be fully automated. The welder automatically feeds the flux core wire, and you hold the trigger and weld. These MIG welding fundamentals make Flux-cored welding much less challenging and more manageable for beginners and new welders.

Image credit: https://weldguru.com/flux-core-welding/ 

Which One is Better, Flux Core or Stick Welding?

There is no simple answer, as each method has a different set of advantages and drawbacks. To make an informed choice, consider the projects and applications you plan to tackle. Most importantly, you should evaluate the following:

Metal thickness: FCAW and Stick run hot, but Stick has deeper penetration at the same amps. If your projects include welding thick stock, go for Stick. FCAW can work better if you often tackle thick stock and occasionally medium-thickness metal or some thinner parts.

Welding conditions: Slag welding processes show excellent results when working outdoors. Wind or draft won't blow away the shielding, allowing you to weld defect-free. However, welders prefer Stick when working in harsh outdoor environments. Its portable and durable welding machines can work in extreme conditions. Meanwhile, welders use FCAW for home applications and everyday farm and ranch repairs. You can use it indoors, as long as you provide proper ventilation.

Skill level: If you are new to welding, choose wire welding processes such as MIG or FCAW. The semi-automated working principle is much more beginner-friendly than Manual Metal Arc welding (MMA) or Stick welding.

Costs or speed: Stick welding equipment is initially cheaper, but it is slower and less efficient than FCAW. So, you will have to decide between costs and speed. SMAW’s low equipment and consumable costs are better for occasional home welding projects. The speed and high deposition of FCAW provide better overall cost-efficiency in large-scale, industrial applications.

Personal preferences: In the end, it all comes down to your preferences. If you find one of the methods more suitable for you and your projects, just go for it. In-home or hobby welding, choose the method that fits better your style and preferences.