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I know the show is set up to never have Tom Welling in the suit, taking the mantle of Superman - but how could he, even if he did? Lex certainly knows who he is, and all the other non-powered characters do as well.
Would the Superman of this universe actually have to wear a mask?

Lets be honest any one who knows Clark would know who Superman is as soon as he appeared. The whole Lex thing would be a problem as he should be able to recognise him as well but hey even in the comics where lex has a 12th level intellect he doesn't know and Lex has crossed paths with Clark a few times. Its one of the many wonders of the mythos, perhaps the costume and gel'd hair is what makes it not so noticeable. A flying man with spandex covering his body and underwear on the outside probably takes the attention away from his face who the fuk knows, I dont.

One can only hope. I've always thought that they ruined the Superman mythos by changing everything around.

Lex & the others would certainly notice it's him but let's just hope it gets to that point. Not having him become Superman is a waste of having him go through all these lessons & trials.

since this is the final season I believe,I wouldnt be surprised if in like the last couple of episodes he wore the suit.