Gasless MIG and stick welding both use a protective flux rather than an external gas to shield a weld, but that’s where the similarities end. So, which one should be used for what applications?

Gasless MIG Welding

Gasless MIG is an arc welding process in which a wire electrode is continuously fed through a welding gun into a weld pool. An arc is formed between the wire electrode and base metal, melting the base material while consumable filler wire is deposited, creating the weld. A hollow wire that contains flux is used, which produces a protective layer of slag on the finished weld.

Advantages

• It works well on both thin and thicker materials
• It’s much faster than stick welding, as it’s a semi-automatic process
• Suitable for both indoor and outdoor use

Disadvantages

• It’s more expensive to set up than stick welding
• There are more variables that can potentially cause downtime

Applications

Gasless MIG is commonly used in construction because of its faster welding speeds. It’s also used in manufacturing and any industry that requires the welding of thick sections of steel. It’s also a good choice when working in outdoor or windy conditions.

Stick Welding

Stick welding is an arc welding process in which a power source creates an electric arc between a flux-coated electrode and the workpiece. The electrode is struck against the metal and melted into the joint to form the weld. The flux covering acts as a protective layer for your weld, so no gas is needed.

Advantages

• Equipment and setup are relatively inexpensive and portable
• It’s less sensitive to dirty or rusted metals than gasless MIG
• Suitable for both indoor and outdoor use

Disadvantages

• It has a slower deposition rate, especially compared to gasless MIG
• It’s limited to thicker materials

Applications

Stick welding is suitable for most general maintenance and repair tasks. It’s also used in the construction of steel structures and industrial fabrication. It’s a good choice for heavy metal work and when working in windy or outdoor conditions.