What is the most popular welding process in use today?

The most popular welding process in use today is shielded metal-arc welding (SMAW), commonly known as stick welding. This process has been widely adopted across various industries due to its versatility, simplicity, and effectiveness, especially in outdoor settings and for heavier materials. SMAW is particularly valued for its ability to produce high-quality welds and its effectiveness on rusty or dirty surfaces, which is often a consideration in fieldwork.

The equipment required for shielded metal-arc welding is also relatively inexpensive and portable. This makes it accessible for both small businesses and hobbyists, contributing to its popularity. Moreover, the SMAW technique does not require a supply of external shielding gas, which makes it suitable for different environments, including those with adverse weather conditions.

In contrast, other welding processes such as TIG, FCAW, and plasma arc welding have their specific applications and advantages, but they may not match the widespread usage and familiarity of stick welding in general practice.