The Different Types of Welding Explained

Binding two pieces of metal together has been possible for hundreds of years. However, it has only been in the last few decades that the welding process has evolved, providing different types for different situations with easier application.

Five main types of welding are available today, each with its own pros and cons. Let’s take a look at all the options to give a clear understanding of which is more suitable for every situation.

Introduction to Types of Welding

Welding is a method used in manufacturing to fuse two parts together, typically metals and thermoplastics. However, you can also use this process on wood in some cases.

The welding process uses heat, pressure, or the combination of the two and bonds two substrates together, enabling them to flow together. Sometimes, welders use a separate substance as a filler to help create a stronger hold.

There are various forms of welding, each important for a specific task or material, with five main types used most often.

• Stick Welding
• MIG (Metal Inert Gas)
• TIG (Tungsten Inert Gas)
• FCAW (Flux Cored Arc Welding)
• SAW (Submerged Arc Welding)

Stick Welding

Stick welding, also known as shielded metal arc welding, is the most common approach to arc welding and one of the first forms of this trade. Stick welding is simple, versatile, and affordable, making it a popular option.

This welding technique requires a stick-like electrode to join materials with electric currents. Essentially these electric welding currents create an electric arc between the materials you are welding together.

You will frequently see stick welding or shielded metal arc welding with heavy-duty metals such as carbon steel and cast iron in industrial settings.

MIG Welding

Like stick welding, MIG welding uses the arc welding process to fuse two pieces of metal. However, unlike stick welding, MIG is released on a continuous wire electrode and is delivered into a weld pool along with a flow of shielding gas (such as helium or argon) through a handheld welding gun or torch.

Once the end of the electrode and the metal meet, the base metal will melt, forming a joint.

MIG welding is ideal for thinner materials and often used for auto repairs or assembly.  However, you can also use this process for some thicker materials, too.

TIG Welding

Another popular arc welding process is TIG welding or tungsten inert gas welding. This process was designed in the 1930s by aircraft industries to weld magnesium.

TIG welding requires using a non-consumable tungsten electrode to create a joint weld. When you use a TIG welder, you create an arc between the non-consumable (will not melt) tungsten electrode and the base metal. A weld pool will form from this interaction, and a thin metal wire is hand-fed to the same spot, causing it to melt and create a joint.

An inert shielding gas is also released at this time to protect the welding pool and electrode from oxygen, steering clear of corrosion and slag.

Flux Cored Arc Welding (FCAW)

Flux cored arc welding uses a continuously fed tubular-shaped electrode that is filled with flux and constant voltage to create a joint between two metals.

This type of welder implements the same kind of equipment as MIG welders with a welder, welding gun, wire feeder, and ground clams.

Unlike MIG welders, flux welding machines use different types of wire, “soft-wire,” which is not completely solid. Instead, this wire has a flux core; this material rises to the top of the weld when exposed to create a protective casing while the weld cools. This solidified casing, also known as slag, can be chipped off after the weld is sound.

Submerged Arc Welding (SAW)

The submerged steel arc welding process involves creating an arc of electric current between metal and a continuously fed electrode (using flux and filler metal). This type of welding is often used in steelwork with stainless steel, low alloy, carbon steel, and high-strength steel.

SAW is most frequently used for long welds or when welding thick steel sheets. Like flux cored welding, the flux wire feeds the metal onto the targeted welding joint. Once melted, it becomes a conductor and can be removed once cooled.

FAQs

What is the difference between stick welding and MIG welding?

The most significant difference between MIG and stick welding is the shielding gas and the type of electrode used to create the arch. MIG welding requires a consumable solid wire fed by a machine with separate shielding gas. Stick welding uses a coated electrode that creates its own gas.

What are the advantages and disadvantages of TIG welding?

The benefits of TIG welding include high precision, versatility, and produces no slag. The disadvantages of TIG welding include needing excellent hand-eye coordination, the time it takes to do it, and the high cost of the materials.

Can I use MIG welding on thin metal?

Yes, MIG welding is one of the best options for thin metals. However, you must have great precision and patience to create a clean weld.

What type of welding is best for outdoor use?

The best type of welding for outdoor use is stick welding. This is a good choice because it can weld in poor conditions, the wind won’t affect the weld, it can weld rusty and dirty materials, and no preparation is required.

Is it possible to switch between different types of welding during a project?

While it is possible to switch between two types of welding during a project, this can be very time-consuming since it would require different welding equipment, and not all types of welding are accessible in all spaces or on all types of metals.