{"id":329,"date":"2021-08-30T14:55:42","date_gmt":"2021-08-30T14:55:42","guid":{"rendered":"https:\/\/welderacademy.com\/?p=329"},"modified":"2021-12-10T15:00:32","modified_gmt":"2021-12-10T15:00:32","slug":"stick-welding-vs-wire-feeders-do-you-know-the-difference","status":"publish","type":"post","link":"https:\/\/welderacademy.com\/stick-welding-vs-wire-feeders-do-you-know-the-difference\/","title":{"rendered":"Stick Welding vs. Wire Feeders: Do you know the Difference?"},"content":{"rendered":"\n

Arc Welding is one of the most popular fabrication processes. It is widely used, highly efficient, and affordable. There are few basic types of arc welding, such as wire feed welding, stick welding, TIG welding, etc. Stick welding and wire feed welding might seem similar to the inexperienced eye, but there are a few key differences present between them.<\/p>\n\n\n\n

If wire feed welding seems unfamiliar to you, it is because it’s a relatively less used term. The more common name is MIG or MAG welding. The main difference lies in the filler metal. Stick welding uses a filler rod, and wire feed welding uses a filler wire. The wire is fed from a spool inside the welding machine.<\/strong><\/p>\n\n\n\n

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There are lots of other differences between stick welding and wire feed welding. The differences lie in the fundamentals like shielding gas, its application, welding technique, etc. In this article, I am going to explore each type down to the core to help you determine stick welding vs wire feeders – <\/strong>what makes them different.<\/p>\n\n\n\n

Basic Differences Between Stick and Wire Feed Welding<\/strong><\/h2>\n\n\n\n

In this article I will be discussing everything there is to know about stick and wire feed welding. But before you head on to the details take a look at this table that I\u2019ve prepared that explains how these two methods compare.<\/p>\n\n\n\n

Traits<\/strong><\/td>Stick Welding<\/strong><\/td>Wire Feed Welding<\/strong><\/td><\/tr>
Stick<\/strong><\/td>Various types of electrode sticks are used.<\/td>No stick is used.<\/td><\/tr>
Wire<\/strong><\/td>No wire filler is used.<\/td>An electrode is used in the form of a wire fed from a spool.<\/td><\/tr>
Separate filler metal<\/strong><\/td>No separate filler metal is used. The electrode is consumable and works as a filler.<\/td>No separate filler metal is used. The wire is consumable and works as a filler.
<\/td><\/tr>
Shielding gas<\/strong><\/td>No need for a separate flow of shielding gas.<\/td>A nozzle supplies shielding gas from a gas tank.<\/td><\/tr>
Deposition rate<\/strong><\/td>The deposition rate is slow.<\/td>Fast deposition rate.<\/td><\/tr>
Welding speed<\/strong><\/td>Slow welding speed.<\/td>Fast welding speed.<\/td><\/tr>
Cleanliness<\/strong><\/td>Slag and weld splatter is formed after welding. Requires rigorous cleaning.<\/td>The surface remains clean. Only a brief cleaning will suffice.<\/td><\/tr>
Expenses<\/strong><\/td>Very affordable.<\/td>Expensive.<\/td><\/tr>
Joint quality<\/strong><\/td>Strong joints.<\/td>Relatively weaker joint.<\/td><\/tr>
Difficulty<\/strong><\/td>Easy to learn, great for beginners.<\/td>Not so easy as stick welding. Requires basic welding knowledge.<\/td><\/tr>
Application<\/strong><\/td>Heavy industrial production.<\/td>Light manufacturing and repairing.<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n

What is Stick Welding?<\/strong><\/h2>\n\n\n\n

Stick welding is the most basic type of arc welding. It is often the first taught welding technique because it is easy to learn. Stick welding gives insights into the basics of welding. So other arc welding types become easier to master.<\/p>\n\n\n\n

If you learn stick welding, you will gain the necessary knowledge about all the other welding processes. You can learn about welding arcs, the basics components of a welding machine, voltage, amperage, metal ratio, etc.<\/p>\n\n\n\n

Stick welding is also known as manual arc welding, manual metal arc welding, and shielded metal arc welding. In stick welding, the welder uses a stick or rod to weld two pieces together. The rod is called an electrode in technical terms. Welders use a consumable electrode in stick welding. The rod melts and deposits to the joint as the welding progresses.<\/p>\n\n\n\n

The stick acts as the filler material. It fills the void between the two base metals, solidifies, and joins them together. Hence it is called filler metal. Due to the stick-shaped filler metal used in this type of welding, its name is stick welding.<\/p>\n\n\n\n

If you have previously heard about other types of welding, you may be already wondering where the shielding gas is. That\u2019s where the altar alias comes into play. As I have already mentioned, stick welding and shielded metal arc welding are two different names of the same type.<\/p>\n\n\n\n

<\/a>The filler rod has coatings of inert substances to protect the weld pool from contamination. When the welding begins, it provides a shielding substance from its coating. Usually, it has a layer of CaCO3<\/sub> which breaks down into CaO and CO2<\/sub> when the arc is formed. So, separate shielding gas is redundant here.<\/p>\n\n\n\n

The manufacturers make the electrode in such a way so that it can provide shielding substances. Due to this reason, you can conduct stick welding in any environment, even outside.<\/p>\n\n\n\n

Parts of a Stick Welding Machine<\/strong><\/h3>\n\n\n\n

Stick welding is the most basic form of arc welding. Following are the most basic components of a stick welding machine:<\/p>\n\n\n\n

  1. Power Supply<\/strong><\/li><\/ol>\n\n\n\n

    The power supply delivers the electricity to the workpiece or base metal through the electrode and the workpiece clamp. It gets electricity from a DC power outlet. It is the main component of any welding machine.<\/p>\n\n\n\n

    The power supply is a box-looking thing that contains a step-down transformer. The transformer lowers the high voltage current to the low voltage current. Modern-day welders have inverters for more efficiency.<\/p>\n\n\n\n

    1. Electrode Holder<\/strong><\/li><\/ol>\n\n\n\n

      The electrode holder holds the electrode. The welding technician operates the electrode holder to control the arc and speed. The power supply delivers electricity to the stick through the electrode holder.<\/p>\n\n\n\n

      To protect the technician from electrical accidents, the holder has insulations. The manufacturers make the holder specifically to maintain a certain angle. Some holders also contain an internal cooling system.<\/p>\n\n\n\n

      1. Workpiece Clamp<\/strong><\/li><\/ol>\n\n\n\n

        The workpiece clamp is connected to the working surface. The power supply delivers electricity to the clamp. So, when the stick touches the working surface, the circuit completes, and electricity flows through the circuit.<\/p>\n\n\n\n

        The workpiece clamp is also called a ground clamp or earthing clamp. Whatever the name is, the principle of the mechanism is the same.<\/p>\n\n\n\n

        1. Electrode<\/strong><\/li><\/ol>\n\n\n\n

          The electrode or the stick<\/a> is the chief component of a welding machine. The electrode holder holds the stick and initiates the arc. It also works as filler material. The operator uses the electrode to control the arc, speed, weld pool, and the formation of joints.<\/p>\n\n\n\n

          For shielding purposes, the electrode has coatings of inert substances. On contact, it releases inert gases that prevent contamination. The type of electrode plays a vital role in the quality of the welding.<\/p>\n\n\n\n

          How Does it Work?<\/strong><\/h3>\n\n\n\n

          Stick welding works following the basic principle of arc welding<\/a>. The power supply del<\/a>i<\/a>vers electricity<\/a> to the workpiece through the earthing clamp. The stick gets electricity from the power supply through the stick holder.<\/p>\n\n\n\n

          When the operator contacts the tip of the electrode with the workpiece, it forms a complete circuit between the two poles. The contact between the stick and the workpiece ignites the arc. This achieves the necessary fusion heat. The workpiece and the stick gradually melt and form a weld pool.<\/p>\n\n\n\n

          The coating of the stick provides gases to protect the weld area from contamination. As the welding progresses, the weld pool is solidified and forms the necessary joint. For stick welding, low voltage and high amperage are most important.<\/p>\n\n\n\n

          The welding machine or the power supply has all the necessary parts to provide the correct voltage and amperage to the work field.<\/p>\n\n\n\n

          Applications of Stick Welding<\/strong><\/h3>\n\n\n\n

          Stick welding used to be a widely applied form of arc welding. As time went by, the advancement of MIG welding and TIG welding has limited the use of the age-old technique. But it still has diverse applications in various industries.<\/p>\n\n\n\n

          There are two reasons behind using stick welding: it’s cheap and easy to learn. It doesn’t require any high-end equipment. MIG welding requires the supply of inert gas. TIG welding requires separate filler material as well as an inert gas. Stick welding has all of these features built-in.<\/p>\n\n\n\n

          Following is some of the industries where we use stick welding:<\/p>\n\n\n\n