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What are the Types of Welding?

3/18/2016

19 Comments

 
There are more than thirty different types of welding, from simple oxy-fuel (using a flame) welding to high-tech processes such as laser beam welding. This article will explain the differences between the four most commonly used welding processes of MIG, TIG, Stick and Flux- Cored arc welding. Though these processes can be done by automated equipment, they are mostly practiced by trained welders.

​Stick - Shielded Metal Arc Welding (SMAW)

Stick Welding
Shielded Metal Arc Welding, commonly called Stick, is a welding process that uses an electrode (welding rod) to carry the electric current and provide the majority of the weld metal. The electrode consists of a core wire coated in flux. An electric arc is created across the gap when the energized circuit and the electrode tip touches the work piece and is withdrawn, yet still within close contact, generating temperatures of approximately 6500°F. This heat melts both the base metal and the electrode creating the weld. During this process, the molten metal is protected from oxides and nitrides in the atmosphere by a gaseous shield created by the vaporizing of the flux coating. The electrode produces a slag covering on the finished weld.

​Typical Uses
: Steel Erection, Heavy equipment repair, Construction, Pipeline Welding
Advantages
  • Low Cost Equipment
  • Portability
  • No need for shielding gas (can be used outside during rain or wind)
  • Works on dirty or rusty metal
Disadvantages
  • Lower consumable efficiency (waste is produced)
  • Difficult to use on thin materials
  • High operator skill required

​TIG - Gas Tungsten Arc Welding (GTAW)

Gas Tungsten Arc Welding, commonly called TIG or Heliarc, is a welding process that uses a non-consumable tungsten electrode to heat the base metal and to create a molten weld puddle. An autogenous (no filler metal) weld can be created by melting two pieces of metal together. An external filler rod can be added into the molten puddle to create the weld bead and increase mechanical properties. Like the GMAW process, the molten weld puddle needs to be shielded by an external gas supply. The most commonly used shielding gas is argon, but argon/helium mixtures can be used on heavy aluminum. GTAW can be used to weld most alloys.
​
Typical Uses: Aerospace welding, piping systems, motorcycles or bikes
TIG Welding
Advantages
  • Clean, high quality welds
  • Ability to weld very thin materials
  • Wide range of alloys can be welded
  • Spatter free welds
  • Highly aesthetic weld beads
Disadvantages
  • High operator skill required
  • High cost equipment
  • Lower deposition rates
  • Need external shielding gas
  • Material must be free of rust and dirt

​MIG - Gas Metal Arc Welding (GMAW)

MIG Welding
Gas Metal Arc Welding, commonly called MIG welding, is a process that uses a continuously fed, solid wire electrode through a welding "gun." The operator pulls a trigger on the welding gun, which feeds the consumable electrode through. An electric arc forms between the electrode and the base material, which heats the base material, causing it to melt, and join.  The molten weld metal is protected from oxides and nitrides in the atmosphere by an externally supplied shielding gas. The most commonly used gas is carbon dioxide or a mixture of argon and carbon dioxide. The GMAW process can be used to weld a wide range of alloys including carbon steel, stainless steel, magnesium, nickel, copper, silicon bronze and aluminum.
​
Typical Uses: Small to large manufacturing, Auto Body, Fabrication
Advantages
  • Higher Electrode Efficiency (Less Waste)
  • Lower Heat Inputs
  • Minimal weld clean up
  • Reduced Welding Fumes
  • Easiest to learn
Disadvantages
  • Need external shielding gas
  • Limited positions (no vertical or overhead)
  • High cost equipment
  • Cannot weld thick materials
  • Material must be free of rust and dirt

​Flux-Cored Arc Welding - (FCAW)

Flux-cored Arc Welding is a welding process similar to GMAW, in that it uses a continuously fed electrode, but uses a tubular wire filled with flux instead of a solid wire. There are two types of flux-cored wire, self-shielded and dual shield. Self-shielded is used without the aid of an external gas shield and uses the flux to shield the molten weld puddle. Dual shield uses the flux and an external shielding gas to protect the molten weld puddle. Typical shielding gases are carbon dioxide and argon/carbon dioxide mixes. Self-shielded wires are optimal for outdoor use, even in windy situations. Both wires produce a slag covering on the finished weld.
​
Typical Uses: Thick materials, Steel Erection, Heavy Equipment construction or repair
FCAW Welding
Advantages
  • Higher Electrode Efficiency (Less Waste)
  • Lower Heat Inputs
  • Minimal weld clean up
  • Reduced Welding Fumes
  • No need for external shielding gas
Disadvantages
  • Creates slag
  • Not recommended for thin materials
  • A lot of smoke is generated
  • High cost equipment
19 Comments
Kenneth Gladman link
4/25/2018 06:27:08 pm

I need some high quality welding techniques for the project I want done. It seems like GTAW seems like the option that would work best. With the versatility and high aesthetic beads, it seems like the best.

Reply
Jenna Hunter link
5/30/2019 08:17:49 pm

I really liked what you said about the different types of welding. This would be really helpful for my cousin to know so that he could use their services. It would also be really helpful if he could get a professional to help him out.

Reply
Brothers Gas link
7/10/2019 01:32:02 am

Wonderful explanation on different types of welding used in the industries. I am very greatful for the author who have shared this post.

Reply
Larry Weaver link
8/13/2019 12:48:39 pm

I had no idea that there are over 30 different types of welding methods. My dad is building a car, and he will need to do some welding for the project. I'll let my dad know that there are different types of welding methods so he can find the one that is right for him.

Reply
Welding Monitor link
8/21/2019 11:09:36 am

It was surprised to learn that there are 30 different types of welding. This article provided detailed information about the four most commonly used techniques of welding. Thanks for sharing!

Reply
Derek McDoogle link
8/29/2019 02:35:13 pm

I did not know that an autogenous (no filler metal) weld can be created by melting two pieces of metal together. My dad told me that he would like to install an iron gate but he wants to design it. I will tell him to look for a professional to help him find out what is the best option for him.

Reply
Brad Erwin link
10/25/2019 01:35:38 pm

I didn't know that there are more than thirty different types of welding! My brother recently discovered the need to have a part on his truck welded back together so that he can keep his tailgate in place. I will let him know that he needs to do research on the type of welding he needs to be done before looking for a good welding service in his area.

Reply
Sabrina Addams link
11/21/2019 07:47:52 pm

Wow, it's amazing to learn that in stick welding, an elective arc is created by close contact with the circuit and the electrode tip, reaching about 6500 degrees Fahrenheit! The welding process amazes me and sounds like a lot of expertise and training are involved since such high temperatures are reached. If I needed something to be welded, I would probably hire a professional service to ensure the proper safety and execution of the job.

Reply
Greta James link
11/25/2019 04:54:39 pm

I really like that you outlined the different kinds of welding and what they are useful for. My sister is thinking she wants a custom metal gate made for her fence. I really appreciate your tip that flux-cored welding is not good for thin materials. I am sure professionals would know what kind of welding is best of the job.

Reply
rachel frampton link
1/23/2020 05:41:18 pm

My dad would like to have a customized chair made out of steel. Surprisingly, there are different types of welding such as gas metal arc welding which deals with solid wire electrode through a welding gun. I guess it would be best if we'll just look for a commercial welding service because since my dad is not an expert on this, he might accidentally hurt himself.

Reply
engineering companies in Auckland link
3/19/2020 06:15:20 am

I really appreciate your hard work to write this kind of amazing and informative blog for us. Your blog What are The Types of Welding and welding process amazes me and sounds like a lot of expertise and training. Keep posting such amazing blogs dude. Waiting for the new one.

Reply
Addy Parker link
3/25/2020 10:19:25 am

The insights you have provided about the different types of Welding is very relevant. It will help us welders to hone our skill and widens our knowledge about this field of work.

Reply
John Douglas link
5/29/2020 09:41:46 am

Metal welding is more popular and everyone always thinks first of arc welding. Every welder image is of an arc welder. But there are many more types, and it isn't all just metal.

Reply
Adam Golightly link
7/7/2020 07:25:05 pm

It was interesting to learn about how dual shields can protect the molten weld puddle with the flux and interior shielding. I can see how it could be really useful for a business to make sure that it can be safe and can protect the employees while being easier for them. Getting some help from a professional could be really useful and make sure that the process will be a lot faster.

Reply
David link
7/11/2020 12:10:48 pm

I'm really appreciate your work this article is so helpful for the beginners in this field. can you please further discuss about mig and tig welding. thank you in advance.

Reply
Chris Paul link
9/28/2020 03:38:13 am

Welding is an important skill in our society. MIG and TIG welding are largely used in our society. It is good to have an understanding about them so we can select best welding equipment for our use.

Reply
Shaylee Packer link
9/30/2020 08:39:43 am

You mentioned that one of the advantages of stick welding is that it works with dirty or rusty metal. My father is needing to have a section of metal repaired on his shop, and wants to know how to go about doing that. I will have to let him know that he can hire a company that does stick welding, and that should do the trick.

Reply
Sam Chadwick link
1/18/2021 10:14:26 am

It was mentioned that gas metal arc welding is the type that is typically used on auto body fabrication. My brother is working on building a custom car and needs some help welding the body of the car together. I will have to let him that it may be a good idea to look into a welder that offers MIG welding.

Reply
Taylor Hicken link
2/21/2021 08:31:04 pm

You made a good point when you shared that there are more than 30 different types of welding techniques in the industry. It is important to understand each one of them and decide the right one that is suitable for your application. I would like to think if a company is looking for a reliable metal fabrication service, it should consider looking for the one that can offer the right type of welding.

Reply



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  • Products & Services
    • Welding & Cutting Equipment >
      • Free Welding Productivity Analysis
    • Gases >
      • Free Gas Application Analysis
      • Industrial & Welding Gases
      • Medical Gases >
        • Medical Oxygen
      • Bulk & Microbulk Gas
      • Specialty Gases
    • Welder Rentals & Repairs
    • Engineering
    • Machine Tools
    • Welding & Cutting Automation
    • Used Welding Equipment
  • Welder Training
    • Program Overview >
      • Fundamentals of Welding
      • Intermediate Welding >
        • Intermediate Stick
        • Intermediate TIG
        • Intermediate MIG
      • Advanced Welding >
        • Advanced Stick
        • Advanced TIG
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      • Welding Basics
      • Custom Classes & Open Practice Time
    • Pricing and Class Schedule
    • How to Register
    • Tour Our Facility
    • Why Earlbeck Technical Center
    • On Site Training
    • Frequently Asked Questions >
      • Are student loans, financial aid, or scholarships available?
      • How long does it take to complete the program?
      • Do you offer job placement?
      • How Much Money does a Welder Make?
      • What is the Job Outlook for Welders?
      • What should I bring for my first day of class?
  • Weld Testing
    • Welder Certification
    • Send In Weld Testing
    • AWS D1.1 Send in Test Kits
    • Frequently Asked Questions >
      • How much does a welding certification cost?
      • How do I become qualified for bridge work?
      • Does a Welding Certification Expire?
      • What is an ATF Test?
      • What Welding Certification Do I Need?
      • Why Should I Become a Certified Welder?
  • Welding 101 Blog
  • Locations & Contacts
    • Baltimore, MD
    • Beltsville, MD
    • York, PA
    • Scranton, PA
  • More...
    • Why Earlbeck
    • History
    • Photo Gallery
    • Resources
    • Testimonials
    • Our Policies