SMAW vs FCAW — Stick vs Flux-Cored for Structural Steel
Compare SMAW vs FCAW-G (gas-shielded) vs FCAW-S (self-shielded). FCAW deposits 2 to 3 times more metal per hour than SMAW. FCAW-S eliminates external shielding gas for outdoor work. All three variants are prequalified under D1.1:2025 Table 5.1 for structural welding.
Side-by-Side Comparison
| Property | SMAW | FCAW-G | FCAW-S |
|---|---|---|---|
| Deposition rate | 1–5 lbs/hr | 5–12 lbs/hr | 4–10 lbs/hr |
| Filler metal form | Coated stick electrode | Gas-shielded tubular wire | Self-shielded tubular wire |
| Shielding method | Flux coating decomposition | External gas + flux core | Flux core only |
| Common classifications | E7018, E6010 | E71T-1, E71T-1C | E71T-8, E71T-11 |
| D1.1 preheat category | A or B (depends on electrode) | B (low hydrogen) | B (E71T-8) or A (E71T-11) |
| Wind tolerance | Good | Poor | Excellent |
| All-position capable | Yes | Yes | Yes |
| Prequalified D1.1 | Yes (Table 5.1) | Yes (Table 5.1) | Yes (Table 5.1) |
How Each Process Works
SMAW (Shielded Metal Arc Welding) uses a consumable electrode coated with flux. An arc forms between the electrode tip and the workpiece, melting both the electrode core wire and the base metal. The flux coating decomposes to produce shielding gas and slag that protects the molten weld pool from atmospheric contamination. After each electrode is consumed, the welder replaces it. This start-stop cycle limits deposition rate to 1–5 lbs/hr.
FCAW-G (Gas-Shielded Flux-Cored Arc Welding) feeds a continuous tubular wire electrode through a welding gun. The wire contains a flux core that produces slag to protect the weld, while an external shielding gas (typically 75% Ar / 25% CO₂ or 100% CO₂) provides additional atmospheric protection. The combination of flux and gas shielding produces clean, low-hydrogen weld deposits at 5–12 lbs/hr. FCAW-G is the dominant process for shop fabrication of structural steel.
FCAW-S (Self-Shielded Flux-Cored Arc Welding) also uses a continuous tubular wire, but the flux core is formulated to provide all necessary shielding without external gas. This makes FCAW-S the preferred process for outdoor field erection where wind disperses external shielding gas. Deposition rates of 4–10 lbs/hr are lower than FCAW-G but still 2 to 3 times higher than SMAW.
Hydrogen Control Differences
D1.1:2025 Table 5.11 assigns preheat categories based on hydrogen risk. FCAW-G inherently deposits low hydrogen because the gas shielding and flux core chemistry are designed to minimize hydrogen pickup. All FCAW-G welding falls under Category B (low hydrogen processes).
FCAW-S varies by electrode classification. E71T-8 is classified as low hydrogen and falls under Category B, matching FCAW-G and SMAW with E7018. However, E71T-11 is not classified as low hydrogen and falls under Category A, which requires higher preheat temperatures above 3/4 inch material thickness.
SMAW preheat category depends on the electrode. Low-hydrogen electrodes like E7018 fall under Category B. Non-low-hydrogen electrodes like E6010 fall under Category A.
When specifying FCAW-S for structural work where low hydrogen is required, always specify E71T-8 (Category B), not E71T-11 (Category A). This single classification choice changes your preheat requirements on every joint above 3/4 inch thickness.
When to Use Each Process
SMAW for field repairs and remote locations: SMAW requires only a power source and electrode holder. No wire feeder, no gas cylinder, no gas lines. For field repairs, maintenance welding, and remote locations where equipment portability matters, SMAW remains the simplest option. E6010 and E6011 electrodes also handle dirty or rusty material better than tubular wire processes.
FCAW-G for shop fabrication: FCAW-G provides the highest deposition rates (5–12 lbs/hr) with consistent, low-hydrogen weld deposits. The continuous wire feed eliminates electrode change downtime. For high-volume shop fabrication where wind is not a factor, FCAW-G delivers the fastest production rates and lowest cost per foot of weld.
FCAW-S for outdoor and field erection: FCAW-S eliminates the external shielding gas requirement entirely. Wind that would disperse GMAW or FCAW-G shielding gas has no effect on FCAW-S because all shielding comes from the flux core. For structural steel erection, bridge construction, and any outdoor application where wind exposure is unavoidable, FCAW-S with E71T-8 provides high deposition rates with low-hydrogen deposits.
Frequently Asked Questions
Yes, FCAW-S electrodes are prequalified under D1.1:2025 Table 5.1. Self-shielded flux-cored electrodes like E71T-8 are classified as low hydrogen and fall under Table 5.11 Category B for preheat. E71T-11 is also prequalified but falls under Category A (non-low-hydrogen) which requires higher preheat temperatures above 3/4 inch material thickness.
FCAW-G (gas-shielded) produces higher deposition rates and cleaner weld metal, making it the preferred choice for shop fabrication. FCAW-S (self-shielded) eliminates the external shielding gas requirement, making it the preferred choice for field erection and outdoor welding where wind disperses shielding gas. Both are prequalified under D1.1 and both produce code-compliant structural welds.
FCAW-G electrodes and SMAW with E7018 both deposit low hydrogen and fall under D1.1 Table 5.11 Category B. FCAW-S varies by classification: E71T-8 is low hydrogen (Category B), while E71T-11 is not low hydrogen (Category A). When low hydrogen is required, specify E71T-8 for self-shielded applications, not E71T-11.
SMAW deposits 1 to 5 lbs/hr depending on electrode diameter and position. FCAW-G deposits 5 to 12 lbs/hr with continuous wire feed and gas shielding. FCAW-S deposits 4 to 10 lbs/hr with self-shielded wire. FCAW processes provide 2 to 5 times the deposition rate of SMAW, which directly reduces welding labor time on multi-pass joints.