Submerged Arc vs Stick: Which for Thick Steel?

Two arc processes that handle thick steel

Submerged arc welding and stick welding are both arc processes that handle thick steel, but they serve different jobs. Submerged arc welding, often called SAW, is described by YesWelder as a high-productivity, wire-fed process where a hidden arc under granular flux makes long, flat-position welds on thick steel. Stick welding, also known as SMAW or arc welding, runs on coated rods and needs no shielding gas, as Everlast notes.

The distance between the two shows up in where each process lives. Miller's site presents a SubArc system in a case study at a heavy-equipment plant, which tells a buyer that SAW is production machinery. Stick welding is the process a buyer finds in a retail welder lineup.

A buyer asking "submerged arc vs stick" is usually reading about heavy fabrication, not shopping for the two processes side by side. The comparison matters because it explains why industrial shops use a wire-fed system with flux, and why a stick welder remains the portable, no-gas bench process you can actually buy.

Deposition rate: a continuous wire or a burning rod

The first thing a buyer hears about SAW is deposition rate: how much filler metal a process can lay down over time. SAW is wire-fed, so the wire arrives continuously as the joint runs, which is why YesWelder calls it high-productivity. Stick welding uses a rod that burns down and must be replaced, so the arc stops between rods.

This article does not put a number on that difference, and no page here measures it. The structural point stands: a wire-fed process keeps feeding metal without a stop, while a rod process stops for every new electrode. That is why production shops use SAW on long, thick joints, and why a stick welder suits repair work where a machine has to be moved to the job.

For the buyer, deposition rate is a context word, not a buying signal. You will not choose a stick welder because it deposits slowly or quickly; you will choose it because it is the accessible machine for your shop. The guide to stick welders compares machines on stated details, and the 200 amp guide covers higher output if you need it.

Slag: every arc process leaves a cover

Both processes leave slag, the coating that forms over a completed weld. In stick welding, the rod coating creates the slag and the welder knocks it off between passes. In SAW, the granular flux covers the arc and the weld; after the weld cools, the flux layer and slag are removed.

For a buyer, the difference is system versus hand tool. SAW's flux is part of a production setup: granular flux is fed over the joint, and the layer is handled after the weld. Stick slag is a chipping hammer job at the bench or on site. Neither point is a reason to choose one for a home shop, but it explains why SAW stays in industrial buildings.

If you are new to welding, the word "slag" tells you something practical: every arc process leaves a cover that has to be cleaned before the next pass. The maker's manual for the machine you pick says how to handle slag for that model. This article's job is to name the difference, not to give steps.

Operator skill and the position of the joint

Operator skill is where the two processes diverge for a buyer. Everlast describes stick welding as very common among first-time welders, and part of that reach is in the setup: a rod, a holder, a ground clamp, and no shielding gas. YesWelder places SAW in a different world: long, flat-position welds on thick steel, with the arc hidden under flux.

Position is the other half of the story. YesWelder ties SAW to flat-position welds, which is a production building statement. Stick welding is the process you take to a fence or a trailer on the ground, and the machine you buy for that job is a stick or multi-process unit.

The practical reading is simple. SAW hides the arc under a granular cover, which makes it a production method for flat work. Stick welding is the process you run in the field, and the process a new buyer will actually see on a machine for sale. The stick versus flux core page and the processes for thick steel page sort out the process words.

What a welder buyer should take from the comparison

If you are choosing a welder, the comparison answers one question quickly: SAW is not a garage machine. It is a dedicated system with a wire feed and flux handling, built for production. Stick welding is the process on the shelf, and it is the conventional pick for thick steel at home, on a farm, or in a small shop. The best stick welders guide is the place to start.

If you need more output, the 200 amp welders guide covers machines with higher top amps. If you want one machine for several processes, the multi-process welders guide explains what a single unit can do. The general best welder guide puts the whole lineup in one place.

For the trade side of the question, the American Welding Society is the organization that runs certification and education for welding careers, and its site lists courses, standards, and local sections. A buyer who wants to move from a first machine to a trade can start there.

Nothing on this site maps a process to a metal thickness, and this article does not claim that either process is better for a specific plate size. The advice stays at the level of which machine to buy: stick for the bench, SAW for the production line.

How the process words show up on a listing

On a welder title, you will not see SAW offered to consumers. What you will see is "stick", "arc", "SMAW", or "MMA" as the process word, plus a top amp figure such as 160 or 205 and an input voltage: 120V, 240V, or dual voltage. Forney's stick welding line leads with figures of this kind, and YesWelder's stick machines do the same.

A title that says "gasless" usually means a flux-cored wire on a MIG-style machine, not SAW. A title that mentions "sub arc" or "submerged" is describing an industrial system you will not buy here.

Before you buy, read the input voltage on the title: 120V, 240V, or dual voltage tells you the supply the maker expects. This site never says where to plug a machine, and the maker's manual is the only authority on the supply it needs. The input voltage page explains the question in words.

What to pick for your situation

Questions

Can I buy a submerged arc welder for my garage?

Not as a practical choice. SAW is an industrial system with a wire feed and granular flux handling. For a garage or farm, a stick welder is the conventional machine.

Does stick welding make slag too?

Yes. The rod coating forms a slag layer over the weld that is removed after cooling. SAW's granular flux also forms a cover that is removed after the weld cools.

Why do production shops choose sub arc for thick steel?

YesWelder describes SAW as a high-productivity, wire-fed process that makes long, flat-position welds on thick steel. The continuous wire feed avoids the stops that a stick rod requires.

Do I need shielding gas for stick welding?

No. Everlast notes that stick welding, also called SMAW or arc welding, needs no shielding gas, which is part of why it is common among first-time welders.

Are SAW and stick the same process?

No. SAW runs a continuous wire under granular flux, while stick burns a coated rod. The two are separate processes with separate equipment.

Which process should I pick between the two?

Stick welding. SAW is not a retail machine. Start with the best stick welders guide, then the 200 amp guide if you need more output.

Is sub arc the better choice for a small fabrication shop?

For a one-person shop, a stick welder or a multi-process machine is the practical buy. SAW belongs to production lines, not a small bench.