This is awesome stuff guys. I was asking age because I wanted to see if the old timers leaned towards stick and the young guns towards mig. This is somewhat true but not conclusive.
I never asked about flux core. Maybe that's the best of both worlds. On a 240v machine you can get darn good penetration on thicker materials and have better control than stick.
I do not neceassarily think age has anything to do with it. Really it boils down to how the welding process applies to the person or business as well as the target material to be welded. Target material to be welded in business world are almost always shiny brand new metal. Backyard shop and the material is almost always dirty rusty metal.
In big business: "Time is Money" and even ultra expensive welding machines can quickly pay for themselves very quickly. Even a few minutes in timesavings really add up over 24 hours a day and 365 days a year with a large deptmartment of workers. The fastest process will easily save big business money even if the initial investment for equipment is immense.
In smaller businesses: The volume may not be there to invest in ultra high dollar equipment like a big business could , but mid-level priced equipment that provides the best compromise of time-savings and appearance is very important. Many small shops get a good portion of their business from "word of mouth advertising" - and good appearance will only help that.
Backyard shop, farmer, homeowner, or hobbyist type guy: Most only need an affordable machine as there is absolutely no one else to pass the costs onto other than himself. Really we only need something that can produce sound welds affordably - time savings is secondary and to an extent even appearance is secondary. While a stick machine will not always be the ideal best process a used $100 AC buzzbox or better yet a used $200 AC/DC buzzbox will cover so many applications for a minimal investment - and most importantly nearly zero in consumable expenses, maintenances costs, and upkeep. No other process allows you to do so much with so little in investment dollars.
As for flux core in a wire feeder:
I would not call it the best of everything as it has advantages and dis-advantages too just like every other welding process does. Just to name a few disavantages: Thin metal ability is compromised with flux core wire over mig gas, flux core wire is more expensive to buy, and dirty rusty metal will still bring even a $2000 wire feeder to its knees where a $100 stick machine will breeze right along.
