Weld Support Parts Blog

Category: Stick Support

Stick machines, consumables, parts breakdowns, and accessories

Stick vs TIG: Process Choice Explained
When it comes to welding, two of the most commonly compared processes are Stick and TIG. While both get the job done, they serve different purposes and skill levels. Choosing between the two depends on your project needs, material type, and how much precision you require.

What Is Stick Welding?

Stick welding, also known as Shielded Metal Arc Welding (SMAW), uses a consumable electrode coated in flux. When struck, it creates an arc that melts both the rod and the base metal. The flux coating produces a gas shield and slag to protect the weld.

Advantages:
- Works well outdoors and in windy conditions
- Handles dirty, rusty, or painted metal with ease
- Lower equipment cost and easier to transport
- Great for thicker materials and structural work
Drawbacks:
- More spatter and smoke
- Requires frequent electrode changes
- Less precise and harder to use on thin metals
Stick is ideal for farmers, construction crews, pipefitters, and anyone needing durable welds in tough conditions.

What Is TIG Welding?

TIG (Tungsten Inert Gas) welding, or Gas Tungsten Arc Welding (GTAW), uses a non-consumable tungsten electrode and a separate filler rod. An external shielding gas, typically argon, protects the weld zone from contamination.

Advantages:
- Extremely clean, precise welds
- Superior control for thin metals
- No slag, less cleanup
- Excellent for stainless steel, aluminum, and exotic metals
Drawbacks:
- Slower process with a steeper learning curve
- Requires very clean materials
- More expensive equipment
- Not ideal outdoors due to shielding gas sensitivity
TIG is the go-to choice for aerospace, automotive fabrication, and high-end stainless or aluminum work.

Which One Should You Choose?
- For Beginners: Stick welding is more forgiving and better for field repairs or structural projects.
- For Professionals or Precision Work: TIG offers unmatched control and aesthetic quality.
Also consider your material type: Stick handles steel and cast iron well, while TIG excels on aluminum, magnesium, and thin stainless steel.

Final Thoughts

Both Stick and TIG welding have their place in the workshop. Stick is tough, fast, and field-ready. TIG is refined, clean, and ideal for detail-oriented work. Choose based on your welding environment, the material at hand, and your comfort level.

Need gear for either process? Check out our curated tools and accessories in the Arc Weld Store to get started the right way.
July 16, 2025
Stick Welder Showdown: Miller Maxstar 161 S vs ESAB Rogue
Introduction & Overview

When it comes to stick welding, the Stick Welder Showdown: Miller Maxstar 161 S vs ESAB Rogue ES 151iP PRO sets the stage for a head-to-head battle between two of the most popular welding machines on the market. Both welders are known for their reliability and performance, making them crucial tools for both amateur and professional welders. Understanding their key differences can help buyers make informed decisions and ensure they select the right welder for their needs.

Key Features

The Miller Maxstar 161 S is known for its portability and efficient power usage, often highlighted by its Auto-Line power management technology. This makes it ideal for use in different environments with fluctuating voltages. On the other hand, the ESAB Rogue ES 151iP PRO stands out with its built-in PFC (Power Factor Control) circuit, which optimizes energy efficiency and reduces power consumption. Both machines capitalized on lightweight and easily transportable designs, but the Rogue offers additional protection with its sturdy, weather-resistant casing.

Pros & Cons
- Pros:
  - Miller Maxstar 161 S: Auto-Line technology for voltage adaptability, lightweight design, reliable arc performance.
  - ESAB Rogue ES 151iP PRO: Robust build, PFC for energy efficiency, portable with weather protection.
- Cons:
  - Miller Maxstar 161 S: Higher price point, fewer advanced features.
  - ESAB Rogue ES 151iP PRO: Slightly heavier, fewer output settings.
Who It’s For

The Stick Welder Showdown: Miller Maxstar 161 S vs ESAB Rogue ES 151iP PRO caters to users requiring robust, portable solutions. The Miller Maxstar 161 S is perfect for tradespeople who frequently encounter variable power sources, whereas the ESAB Rogue ES 151iP PRO suits those needing a durable device for outdoor or rugged environments. Both are excellent for home DIYers, maintenance workers, and professional welders focusing on efficiency and reliability.

What Makes It Unique

What sets these welders apart is their unique incorporation of energy efficiency technologies. The Miller Maxstar 161 S utilizes Auto-Line technology for seamless power adaptability, while the ESAB Rogue ES 151iP PRO offers a PFC circuit, reducing the risk of tripping breakers. Both machines excel in portability but with different strengths, ensuring users have options tailored to specific working conditions and power requirements.

Buying Tips

When choosing between the Stick Welder Showdown: Miller Maxstar 161 S vs ESAB Rogue ES 151iP PRO, consider the environments you will primarily work in. If you frequently move between job sites with uncertain power stability, the Miller Maxstar’s adaptability is invaluable. However, for consistent operations in more demanding environments, the ESAB Rogue’s robust construction is ideal. Consider investing in quality protective gear and compatible accessories like foot pedals or electrodes to maximize your machine’s performance.

Price Comparison: Miller Maxstar 161 S vs ESAB Rogue ES 151iP PRO

When it comes to price, the ESAB Rogue ES 151iP PRO comes in at a noticeably lower cost compared to the Miller Maxstar 161 S. On average:
- ESAB Rogue ES 151iP PRO retails between $500–$650, depending on the kit and seller.
- Miller Maxstar 161 S typically lands in the $950–$1,100 range.
That’s a price difference of $400–$500, which is substantial if you’re on a budget or just need a solid stick welder for light-to-medium duty work.

The Rogue offers impressive arc performance, dual voltage input, and a rugged case — all at a budget-friendly price. On the other hand, the Maxstar 161 S justifies its premium with exceptional build quality, smoother arc characteristics, and a trusted name for jobsite reliability.

If cost is your top concern, ESAB wins on value. But if you’re investing in long-term durability and top-tier arc control, the Miller might be worth the upgrade.

Conclusion

In the Stick Welder Showdown: Miller Maxstar 161 S vs ESAB Rogue ES 151iP PRO, both models exemplify how cutting-edge technology enhances welding efficiency and portability. Whether you prioritize adaptability or durability, these welders offer compelling advantages. By evaluating specific needs and work environments, users can confidently choose the ideal device for their welding endeavors.

We may earn a small commission through Amazon affiliate links, at no extra cost to you.

Generic Miller Electric Stick Welder, Maxstar 161 S Series, Input Voltage: 120V240V – 907709

$2,419.00
Buy on Amazon

Last update on 2025-07-17 / Affiliate links / Images from Amazon Product Advertising API
ESAB® Rogue ES 151IP PRO Stick Welder

Dual voltage input power – flexibility to use on either 120V or 230V outlets
Pulse SMAW functionality – improves heat input control, minimizes distortion of thin materials and helps reduce spatter for higher quality welds
Superior Arc characteristics – smooth and stable performance (including special mode for stick 6010
Generator Compliant – suitable for use with generators. (7kW recommended)
Easy to Use – and adjust a wide range of arc parameters for more control over your weld

$647.90
Buy on Amazon
Last update on 2025-07-17 / Affiliate links / Images from Amazon Product Advertising API
July 13, 2025
Miller Multimatic 220 AC/DC Welder: In-Depth Review & Insights
Miller Multimatic 220 AC/DC Welder In-Depth Review

Introduction & Overview

The Miller Multimatic 220 AC/DC Welder is a versatile welding machine that caters to both hobbyists and professionals alike. Designed for MIG, TIG, and stick welding, this unit stands out because it combines multiple functionalities in a single, compact design. Its ability to weld various materials makes it a game-changer for those who require flexibility and efficiency. Understanding the capabilities of this machine is crucial for anyone considering an investment in welding equipment, and that’s what this in-depth review aims to clarify.

Key Features

The Miller Multimatic 220 boasts an array of impressive features. It operates on both AC and DC, allowing users to weld aluminum, mild steel, stainless steel, and more. Its Auto-Set feature simplifies the setup process, automatically adjusting voltage and wire feed speed for optimal performance based on material thickness. The machine supports a wide range of amperage, ensuring it can handle light and heavy-duty projects with ease. With a durable build and user-friendly interface, the Multimatic 220 balances performance with accessibility.

Pros & Cons
- Pros:
  - Versatile AC/DC capability
  - Auto-Set technology for beginner-friendly operation
  - Excellent build quality and durability
  - Lightweight and portable
  - Comprehensive welding capabilities
- Cons:
  - Higher price point compared to basic welders
  - Some users may find the manual complex
  - A limited duty cycle for heavy-duty tasks
Who It’s For

The Miller Multimatic 220 is ideal for a variety of users, including DIY enthusiasts, metal fabricators, and professional welders. Its versatility makes it suitable for home workshops, where multiple welding disciplines may be required, and is equally effective on-site for industrial tasks. Whether you’re welding automotive parts, building furniture, or repairing equipment, this machine can adapt to meet your needs, making it especially valuable for those who work with diverse materials.

What Makes It Unique

What sets the Miller Multimatic 220 apart from its competitors is its advanced Auto-Set feature, which optimally adjusts settings for the user, making the welding process less daunting for beginners. Additionally, its ability to switch between AC and DC welding gives it an edge in versatility, allowing it to tackle a wider range of materials than many other welders in its class. The robust design ensures longevity, making it a smart investment for those who prioritize quality and reliability.

Buying Tips

When considering the Miller Multimatic 220, think about the specific projects you’ll undertake. Evaluate potential accessories like an additional gas bottle for MIG welding or TIG torches if you plan to work on particularly fine projects. Also, check whether the model you’re interested in is compatible with any of Miller’s additional modular solutions, which can enhance its functionality. Understanding your welding requirements will help you make an informed decision.

Miller Multimatic 220 AC/DC Welder Rebate Offer

Right now, Miller is offering a generous $500 mail-in rebate for the Multimatic 220 AC/DC welder. To claim this rebate, simply visit millerrebatecenter.com and submit your information. Remember, rebate claims must be entered within 30 days of purchase. This special promotion is available from July 1, 2025, through September 30, 2025—don’t miss your chance to save big on this versatile welding machine!

Conclusion

In summary, the Miller Multimatic 220 AC/DC Welder stands out as an exceptional choice for those in need of a reliable, versatile welding machine. With its advanced features and user-friendly design, it caters to a broad audience, from hobbyists to professional welders. Whether you’re experienced or just starting, this machine offers the flexibility needed to tackle a variety of welding tasks effectively.

We may earn a small commission through Amazon affiliate links, at no extra cost to you.
Miller 907757 Multimatic 220 AC/DC Multiprocess Welder – Versatile Multi-Process MIG, Flux-Cored & TIG Welder Machine – Portable Welding Machine with MIG Gun, TIG Torch & Multi-Voltage Plug 120V&240V

All-in-One Capability: Enjoy the freedom to weld any process & take on more projects with the Miller 907757 Multimatic 220 AC/DC Multiprocess Welder; Tackle flux-cored, MIG, Stick & TIG processes like a champ with 1 powerful & easy-to-use Miller welder machine
Intuitive Welding Machines: With QuickTech, our multi-process MIG welder automatically determines polarity, switches to the right process & can recall the settings from your last used process; Saving you time & eliminating the need for manual adjustments
Effortless Setup & Precision Welding: Our multi process TIG welder’s Auto-Set Elite & Pro-Set features help streamline setup & eliminates the guesswork when setting weld parameters; Reducing guesswork for consistent & high-quality welds to improve your job efficiency
Flexible Power Options: Go where the work is with our portable 56-lb multi process welders; These Miller welders come with a multi-voltage plug that lets you connect to both 120V & 240V power receptacles & generators with 10000 Watt (10K) output or higher
Welder Package Inclusions: Our Multimatic 220 AC/DC MIG welding machine comes equipped with essential accessories to get you started; Includes a MIG gun, TIG torch, TIG torch accessory kit, flux-cored wire drive roll, heavy-duty foot control & more

$4,448.00
Buy on Amazon
Last update on 2025-07-17 / Affiliate links / Images from Amazon Product Advertising API
July 11, 2025
Comparing 7018 and 6011 Welding Rods: Understanding Their Unique Strengths and Applications
Welding is an essential process used in various industries, from automotive to construction. The choice of welding rods can significantly impact the quality and strength of the welds produced. Among the myriad options available, two popular welding rods are the E7018 and E6011. Each serves specific purposes and shines in various applications. In this blog post, we’ll explore the differences between these two welding rods, their characteristics, and where each excels.

Understanding the Basics

E7018 and E6011 are designations from the American Welding Society (AWS) that categorize the rods based on their composition and usability.

E7018 Welding Rods
- Composition: E7018 rods are low-hydrogen, iron powder rods typically made up of mild steel with manganese and iron oxide. The ‘E’ stands for electrode, while ’70’ indicates that the rod can produce welds with a minimum tensile strength of 70,000 psi. The ‘1’ denotes that the rod can be used in all positions, and the ‘8’ signifies that it is a low-hydrogen type.
- Coating: These rods have a thick coating, which helps to produce a smooth weld with minimal impurities. This coating enables them to maintain a stable arc and control the hydrogen levels in the weld, reducing cracking.
- Weld Characteristics: E7018 rods produce a strong, ductile weld with excellent impact resistance and crack resistance. They are ideal for structural applications where strength and integrity are paramount.
E6011 Welding Rods
- Composition: E6011 rods are also mild steel rods but feature a different composition that includes cellulose. Much like E7018, the ‘E’ indicates electrode, ’60’ signifies a minimum tensile strength of 60,000 psi, ‘1’ allows for all-position welding, and ‘1’ indicates that it is suitable for use with alternating current (AC) as well as direct current (DC).
- Coating: With a thinner coating, E6011 rods are designed to create a more fluid weld pool, which is advantageous for working on contaminated surfaces.
- Weld Characteristics: The E6011 produces a fast-freezing weld that can penetrate deep, making it suitable for thicker materials or when working in less-than-ideal conditions. However, the weld may have a rougher appearance and less tensile strength compared to E7018 welds.
Key Differences

1. Tensile Strength and Ductility
- E7018: High tensile strength (70,000 psi) and a more ductile weld, making it suitable for structural welds that require high integrity.
- E6011: Slightly lower tensile strength (60,000 psi) but sufficient for many applications. Suitable for thicker materials.
2. Hydrogen Control
- E7018: Low-hydrogen exposure minimizes the risk of cracking, ideal for high-stress applications like pressure vessels or structural supports.
- E6011: Higher hydrogen content may lead to cracking in sensitive applications, though it performs well on dirty or rusted surfaces.
3. Weldability
- E7018: Requires specific preheating and post-weld heat treatment. Best suited for clean conditions.
- E6011: Can weld through rust and contaminants, making it versatile for fieldwork and maintenance tasks.
4. Weld Appearance and Cleanup
- E7018: Produces smooth, aesthetically pleasing welds with minimal clean-up required.
- E6011: Generally leaves a rougher bead that can require more clean-up due to slag.
Applications
- E7018: Commonly used in structural steel applications, pressure vessels, shipbuilding, and any situation requiring high strength and reliability. It is frequently employed in construction and fabrication of bridges, buildings, and heavy equipment.
- E6011: Ideal for maintenance, repair, and farm equipment work, as well as for welding thin materials or in tight spaces. Its ability to work in less-than-ideal conditions makes it a favorite among welders in the agricultural and manufacturing sectors.
Conclusion

Choosing between E7018 and E6011 welding rods depends on the specific requirements of the project you’re undertaking. If you need high-strength, crack-resistant welds with a smooth finish for structural applications, E7018 is the clear choice. On the other hand, if you’re tackling maintenance jobs, working with thicker metals, or need to deal with contaminants, E6011 will serve you well.

Understanding the characteristics, strengths, and ideal applications of these rods ensures that you make informed decisions in your welding projects, contributing to the quality and longevity of your work. Happy welding!
May 28, 2025