(https://inboxq.

com)

 

A Detailed Guide to Di erent Types

of Welding Processes
Welding is a serious job that requires tremendous skill,
extensive knowledge, practice, and most importantly,
commitment. If you are just starting out, the sheer amount of
information on welding can be overwhelming for you.

When I rst began welding 15 years ago, the nomenclature of

welding confused the heck out of me. But I didn’t give up.
You shouldn’t too. To all the welding enthusiasts reading this,
I am going to try and simplify di erent types of welding for
you. My aim is to help you understand the pros and cons of
each type of welding techniques and their individual
applications across various industries.

Let’s hope that by the end of this article, you’ll gure out the
correct type of welding process for your choice of material.

Let’s cut to the chase, shall we?

Contents [hide]

9 Di erent Types Of Welding Processes

1. MIG or Metal Inert Gas/ Gas Metal Arc Welding (GMAW)
2. Stick or Shielded Metal Arc Welding
3. Flux-cored Arc Welding (FCAW)
4. Submerged Arc Welding (SAW)
5. TIG/ Gas Tungsten Arc Welding (GTAW)
6. Plasma Arc Welding (PAW)
7. Electroslag Welding (ESW)
8. Atomic Hydrogen Welding (AHW)
9. Electron Beam Welding (EBW)
Conclusion

9 Di erent Types Of Welding Processes

1. MIG or Metal Inert Gas/ Gas Metal Arc Welding (GMAW)
Industry veterans fondly call it the most beginner-friendly
welding process of all time. They are right. It is the easiest
type of welding technique to master if you are new to this
world. Easy because it takes minimal cleanup and very less
equipment to produce clean, visually-pleasing beads.

MIG stands for Metal Inert Gas. This process is also known as
Gas Metal Arc Welding (GMAW). In this manual process, we
fuse two metal pieces together by continuously feeding the
ller material through a welding wand.
The ller material for this purpose is a consumable wire
electrode. You will also need a shielding gas for this to protect
the arc from external elements e.g wind, dust and rain.

MIG welding (https://inboxq.com/best-mig-welders/) is

commonly used for automotive repair and in the construction
and plumbing industry. On the downside, MIG welds are
considered to be structurally weaker and therefore, less
durable than the more advanced TIG, Flux-cored, and Plasma
Arc Welds. Also, you can’t weld thicker materials using this
technique.

2. Stick or Shielded Metal Arc Welding

This one is an archaic method of welding but still quite
popular among specialists. It is frequently used in repair
works, plumbing, steel fabrication, manufacturing, and
construction industry to fuse bee er metals. Hobbyists and
beginners can polish their skills with this method as it
requires only a couple of inexpensive tools.

It doesn’t require an external supply of shielding gas.

Therefore, you can work on this process outdoors in windy
conditions. This old but gold manual welding technique works
on rusty, dirty, painted metals as well.

This method requires a stick or consumable electrode. This

electrode houses a solid metal rod at its core which is coated
in ux. The electric current forms an arc that connects the
base of the “stick” to the welding metal.

At an intense temperature of 6500°F, the electrode melts into

the weld pool and provides ller material for the joint.

The ux creates a gas cloud during the process to protect the

molten metal from oxidation. Although this method doesn’t
result in the cleanest welds, it can be used on di erent types
of metals. When the gas cools down and settles on the metal,
it creates slag.
Although more dependable than the very basic MIG welding,
stick welding (https://inboxq.com/best-stick-welder/) also has
drawbacks like shallow penetration, cracking and
susceptibility to extreme weather.

3. Flux-cored Arc Welding (FCAW)

Flux-cored isn’t much di erent from MIG welding. It’s

inexpensive, easy-to-apply, versatile, creates neat welds with
very little waste and only some amount of slag. Unlike MIG
that only works on thin materials, FCAW is a high-heat method
that’s only suited for thicker and heavier metals.
Also, it doesn’t require an external supply of gas. This allows
the welder the advantage of working outdoors in windy
conditions.

Just like MIG, this process also requires continuously fed wire
through a torch and a constant supply of voltage power to
create the arc. Instead of a solid wire, you have to use a ux-
cored wire that shields the arc from contamination.

High electrode e ciency results in less debris to cleanup,

resulting in well- nished welds with minimal e ort. You won’t
need an external gas supply, which makes cost-cutting easier.
Due to the ease, e ciency, low cost, and strength of the
welds, this method is extensively used for heavy machine
repair, automotive repair, plumbing, construction, and
maritime industry.

On the downside, you can’t apply ux-cored welding on

thinner metals like aluminum. Plus, the process generates a
lot of welding fumes too.

4. Submerged Arc Welding (SAW)

It’s another welding process using a consumable electrode
method, allowing a deep penetration and strong welds with
very little prep work. This method exclusively deals with
nickel-based alloys and ferrous-steel.

In SA welding, the entire process takes place under the bed of

granular fusible ux. The intense heat makes the ux
conductive which forms a path between the electrode and
base material.
The ux cover keeps emissions, fumes and spatters to a
minimum while also protecting the molten metal from UV
radiation. This is the sole reason why SAW is one of the safest
and most e cient welding methods we have today. The only
true limitation is that it doesn’t work on any type of metal
other than ferrous steel and nickel alloys.

5. TIG/ Gas Tungsten Arc Welding (GTAW)

This method uses a non-consumable tungsten electrode and

inert shielding gas (mostly argon) to form pure, neat, high-
quality welds that can easily withstand years of heavy abuse.
It is a popular method across various big industries including
military equipment manufacturing, maritime, and the
automotive industry to join thick steel sheets, aluminum,
nickel, magnesium, and copper.

For this method, the welder needs to heat up the tungsten

using current. When the electrode becomes conductive, it
forms an arc that melts a metal wire, forming a weld pool.

Meanwhile, a constant ow of gas protects the weld pool from

contamination. You will need both of your hands for TIG
welding (https://inboxq.com/best-tig-welders/), one for
feeding the wire and the other for holding the TIG torch.

This is a very precise method that requires impeccable skills,

focus and practice. That’s mainly because there’s a very small
area between the arc and the base metal for you to work with.

When done correctly, it can form strong and aesthetically-

sound welds with a negligible amount of waste to clean up. It
is mostly used by experienced welders and engineers who
seek a high level of precision and control over the weld area.

6. Plasma Arc Welding (PAW)

Like TIG, PAW also allows the welder a great control over the
arc and accuracy of the welds. For this method, you will need
an advanced torch that features a non-consumable electrode
and a copper nozzle with a small tip.

The electric current is pushed through this nozzle which

pressurizes the protective gas inside the torch, creating
plasma. Next, the plasma gas is heated to a high temperature
and ionized which makes it electrically conductive.
You’ll use this ionized plasma to force the electric arc to the
base metal plate through a very narrow borehole. This
enables the torch to produce an extremely high concentration
of heat in a very small area, leading to deep penetration and
exceptional accuracy.

Therefore, this process is a staple in aircraft manufacturing

industry where we deal with metals 0.015 of an inch. The only
downside is that the preparation and required equipment are
pretty expensive. Since it’s one of the more complex welding
methods, only skilled professionals can perform it.

7. Electroslag Welding (ESW)

This is an automated welding technique that’s frequently used
in steel fabrication and other big industries. ESW method can
be used for welding vertically positioned 25-300 mm thick
metals in a single press.

At the start, the welding machine initiates an arc by passing

electrical current between a consumable electrode and the
base metal plate. This creates a gap that is lled with welding
ux powder. The high heat produced by the arc melts this ux
and produces molten slag on the weld pool.

The slag’s resistance generates high heat that gradually melts

and joins the electrode and base metal pieces. A water-
colored copper shoe is added during the process keeps the
molten slag in place.

While high deposition rate and the ability to fuse extremely

thick metals remain the top advantages of ESW, the
toughness of the weld remains questionable. Moreover, this
method is only applicable to vertically positioned materials.

Electrogas Welding
(https://en.wikipedia.org/wiki/Electrogas_welding) (EGW) is
very similar to this, with one major di erence. In Electroslag,
the slag extinguishes the arc but not in the gas method. EGW
is commonly used in the storage tank and maritime
industries.
8. Atomic Hydrogen Welding (AHW)

This precise method is the most e cient way to fuse

tungsten, a metal possessing a high heat resistance. With
AHW welding, you can produce strong and clean welds
without damaging this precious metal.

In this process, two consumable tungsten electrodes are

placed in a chamber shielded by hydrogen gas. Hydrogen
produces massive heat that forms an arc.

Then, the arc breaks up and recombines the hydrogen

molecules which generates a whopping amount of heat (up to
3000 degrees C). This tremendous amount of heat melts the
tungsten and creates clean and cohesive welds.
While it certainly produces strong welds, the types of
materials it will work on are very limited. No wonder it’s
getting slowly superseded by the more advanced and
versatile gas metal arc welding.

9. Electron Beam Welding (EBW)

This is a fully automated welding process performed by a

machine. It shoots a high-velocity beam of electrons towards
the pieces to be welded. The technique transforms the
electrons’ energy into kinetic energy that melts and fuses the
metal pieces. The whole process takes place in a total
vacuum.
EBW is e ective for fusing two metals with di erent melting
points and heat conductivities. This complex form of welding
is widely used in aircraft engine and fully automated
automotive parts manufacturing.

Conclusion
So these were the 9 main types of welding processes for
welders of all skill levels. There are about 22-23 other types of
welding following the basic principles of these nine
techniques. But you don’t have to dig that deep right now. I
don’t want you to get overwhelmed by too much information
right from the start.

What’s the best welding technique among all of them, you

ask? Depends on your skills, type of material you work with
and budget. The coolest part about having so many methods
available is that both beginners and specialists can explore
new possibilities and scale up their business in their own
time. Hope that helped.

ABOUT THE AUTHOR

Josh Mathews (https://inboxq.com/author/josh/)

 (https://inboxq.com/)
Hi, I’m Josh, the chief editor of Inboxq and I’m borderline
obsessed with everything related to welding. When I am not
toying with heavy-duty tools, I’m either sweating it out in the
gym or playing with my chihuahua. Whenever I run out of
ideas, I go to Burger King for inspiration.

L E AV E A R E P LY

Your email address will not be published.

Comment

Name* Email*

Website
 S U BMIT

MOST POPULAR POSTS

5
Best
110V
Stick
Weld
to
Root
for
in
2020
Revi
and
Buyi
Guid
(https://inboxq.com/best-110v-stick-welder/) (http
110v
stick
weld

10 Best Welding Helmets For Safe And Secure Welding

(https://inboxq.com/best-welding-helmets/)
(https://inboxq.com/best-welding-helmets/)

Best
Wire
Feed
Weld
Our
Favor
of
2020
(http
wire-
feed-
welde

(https://inboxq.com/best-wire-feed-welder/)
 Best
220
MIG
Weld
in
the
Busi
All
You
Need
to
Know
(http
220
(https://inboxq.com/best-220v-mig-welders/) mig-
weld

7 Best TIG
Welders
For
Smooth
And Fine
Results
(https://inb
tig-
welders/)

(https://inboxq.com/best-tig-welders/)
 Best
Flux
Core
Welde
Learn
What
to
Buy
and
What
to
Avoid
(https
ux-
(https://inboxq.com/best- ux-core-welder/) core-
welde

10 Best
MIG
Welders
in 2020
– Review
& Buying
Guide
(https://in
mig-
welders/)

(https://inboxq.com/best-mig-welders/)
 10
Best
Plasma
Cutters
For
Casual
And
Profess
Use
(https:/
plasma
cutters

(https://inboxq.com/best-plasma-cutters/)

Your One-
Stop
Guide to
the Best
Stick
Welder in
2020
(https://in
stick-
welder/)

(https://inboxq.com/best-stick-welder/)
(https://inboxq.com/best-multi-process-welders/)

QUICK LINKS

About Us (https://inboxq.com/about-us/)
Privacy Policy (https://inboxq.com/privacy-policy/)
A liate Disclosure (https://inboxq.com/a liate-
disclosure/)
Contact (https://inboxq.com/contact/)
 POPULAR ARTICLES

Best Plasma Cutters (https://inboxq.com/best-plasma-

cutters/)
Best Stick Welders (https://inboxq.com/best-stick-welder/)
Best Plastic Welders (https://inboxq.com/best-plastic-
welders/)
Best Multi Process Welders (https://inboxq.com/best-multi-
process-welders/)

Copyright 2019 @ InboxQ.com