The 4 Main Types of Welding
Welding is a metal fabrication technique that consists of joining pieces of metal together. It is a satisfying and impressive process to watch, as the bright sparks fly around the welder and the metal melts onto the joint under intense heat.
All welding involves some generated heat and melted metal to connect the two pieces, but there are many different methods to do this. Some of them are more complex than others; some involve metal rods with a “core” and protective material around the outside, while others work similarly to a glue gun, with a rod extruded from the center of the welding tool.
While there are over 30 different types of welding, only four are commonly used. The following descriptions will give you a brief overview of the most common welding techniques out there today.
The 4 Main Types of Welding
A Quick Reference Guide
MIG & MAG Welding
GMAW Welding Diagram
1: Base metal. 2: Solidified weld. 3: Slag. 4: Molten metal. 5: Electrical arc. 6: Shielding gas. 7: Electrode. 8: Contact tube. 9: Nozzle.
These two types of welding comprise what is known as Gas Metal Arc Welding (GMAW). Both forms use a shielding gas and a metal wire fed through the welding gun (like a glue gun). In MIG (Metal Inert Gas) and MAG (Metal Active Gas) welding, an electrical arc is generated between the base metal and an electrode on the tip of the gun, a gas is injected around the point of contact to shield and direct the energy, and a metal wire melts and is deposited onto the joint, fusing it together.
The method is popular because it is easy to learn, does not generate as many fumes or require as much clean up, and it provides a strong, long lasting weld. It is best suited for thinner materials, and is often used in the automotive, construction, boating, and DIY industries.
Perhaps obviously, the primary difference between MIG and MAG welding is whether the shielding gas is inert or active. MIG uses stable, inert gases, such as helium, which enable it to reach very high temperatures without chemical changes. Because MAG welding uses active gases, such as carbon dioxide or oxygen, when the gas is heated it can alter the characteristics of a weld by inducing various chemical elements on the weld bead. This is sometimes desired to enhance joint properties. Both MIG and MAG welding generally follow the same technique and are part of the GMAW family.
TIG Welding
TIG/GTAW Welding Diagram
1: Base metal. 2: Solidified weld. 3: Slag. 4: Molten metal. 5: Electrical arc. 6: Shielding gas. 7: Tungsten electrode. 8: Contact tube. 9: Power and shielding gas input. 10: Head. 11: Filler rod.
TIG welding, or Gas Tungsten Arc Welding, is a more complex welding process that yields an attractive finished product. Similar to the aforementioned MIG method, shielding gas is used along with an electrical arc which is created between the base material and a tungsten electrode to melt the metal. Additional filler metal in the form of a thin rod applied to the melt pool during welding can also be used.
Even though this method is more time consuming and difficult to learn, it is one of the most commonly used welding techniques among professionals due to the high quality, polished look and the ability to create precise welds with thin materials. It is often used for stainless steel welding and in many diverse industries.
Stick Welding
SMAW Welding Diagram
1: Base metal. 2: Solidified weld. 3: Slag. 4: Molten metal. 5: Arc. 6: Shielding gas (optional). 7: Electrode core wire. 8: Projecting sheath. 9: Shielding or heavy coating.
Stick welding, or Shielded Metal Arc Welding (SMAW) is an older, simpler method of welding that does not require a shielding gas and can thus be used in just about any environment. It uses a consumable electrode consisting of a core of metal that is coated with a protective material to prevent corrosion.
Stick welding is not quite as commonly used as the first two methods anymore, but it is portable, inexpensive, and useful in certain situations such as pipeline welding, heavy equipment repair, or steel construction.
Flux Core Arc Welding
Flux Core Arc Welding Diagram
1: Base metal. 2: Solidified weld. 3: Slag. 4: Molten metal. 5: Arc. 6: Shielding gas (optional). 7: Flux core. 8: Tubular electrode. 9: Nozzle.
Flux Core Arc Welding (FCAW) is similar to MIG/MAG welding in that there is a continuously fed electrode (again, like a glue gun), but it uses a tube shaped metal rod filled with flux material instead of a solid rod. The advantages of this type of welding are that it doesn’t require as much clean up, it is very efficient from an energy usage perspective, and it does not require an external shielding gas.
Even though the aesthetic results from FCAW are not quite as “pretty” as other types, many professionals still prefer it due to the fact that it is inexpensive (after the initial investment in the equipment) and easy to learn and use.
Additional Welding Types
Other types of welding include Plasma Arc welding, which is more popular in the aircraft industry, Gas Tungsten Arc welding, Atomic Hydrogen welding, Electron Beam welding, and more. As you can see, there are many options in the welding world. To choose the right method, you must consider the type of materials you are working with, the environment the work will be conducted in, how strong the bond needs to be, how much are you willing to invest, the final finish, and whether you need portability or not.
How can we help?
If you have any additional questions about the welding, laser cutting, or the metal fabrication process, or you are looking for a partner for your next project, contact us at Sattler Manufacturing! We have more than 40 years of experience in Nashville and the Southeastern United States, and our helpful team is standing by to assist you with anything you need. We hope to hear from you soon!