SMAW and Flux-Core Welding
Shielded Metal Arc Welding (SMAW), commonly called stick welding, is the most versatile and portable welding process. The electrode is a flux-coated metal rod; as it melts, the flux coating vaporizes to create a shielding gas cloud and forms a slag layer that floats on the molten pool, protecting it from atmospheric oxygen and nitrogen as it solidifies. Stick welding works well outdoors and on dirty or rusty metal because the flux chemistry compensates for contamination. It is widely used in construction, pipeline work, and structural steel. Electrodes are classified by the AWS system — E6010 indicates 60,000 psi tensile strength, all-position capable, DC+ polarity. Flux-Core Arc Welding (FCAW) uses a continuous wire electrode with flux packed inside the hollow core. It offers higher deposition rates than stick and can be self-shielded (no external gas, good for outdoor work) or gas-shielded (dual-shield, better mechanical properties). FCAW is the dominant process in heavy structural fabrication, shipbuilding, and high-production environments.