Types and Uses are Welding Processes

When you start Knowledge to weld, it’s very easy to overcome by the sheer amount of evidence available on the subject. It can be problematic to begin your welding voyage without expressing the different welding types that exist. Some are easier to learn, while others are rather difficult.

While certain types of welding procedures produce clean drops that are visually attractive and require little to no cleanup, other types produce the strict opposite. What type of metal do you propose for welding? It's kind of a difference. To help simplify the subject, we have compiled important information regarding nine different types of welding procedures.

Types of Welding

1.      TIG Gas Tungsten Arc Welding (GTAW)

2.      Flux Cored Arc Welding (FCAW)

3.      Stick Shielded-Metal Arc Welding (SMAW)

4.      MIG Gas Metal Arc Welding (GMAW)

5.      Laser Beam Welding

6.      Electron Beam Welding

7.      Plasma Arc Welding

8.      Atomic Hydrogen Welding

9.      Electro slag

1. TIG Gas Tungsten Arc Welding (GTAW)   

The first kind of welding is TIG welding, which also drives by the names of Heliarc and gas tungsten arc welding (GTAW). With this kind of welding, the electrode is non-useable and made of tungsten. It is one of the few kinds of welding that can be done with no filler metal, using only the two metals being welded together. You can add a filler metal if you wish, but you will have to feed it by hand. A gas tank is compulsory with TIG welding to provide the continuous flow of gas needed to protect the weld. This means it’s generally better to complete indoors and away from the elements.

TIG welding is a particular welding kind that produces visually appealing welds and doesn’t require cleanup, as there is no spatter. Due to these traits, it is a difficult type of welding that is best reserved for skilled welders.

2. Flux Cored Arc Welding (FCAW)    

This kind of welding is similar to MIG welding. In fact, MIG welders can often perform double duty as FCAW welders as well. Just like in MIG welding, a wire that serves as the electrode and the filler metals is fed through your wand. This is where things begin to change. For FCAW, the wire has a core of flux that makes a gas shield around the weld. This eliminates the requirements for an external gas supply.

FCAW is better matched for thicker, weightier metals since it is a high-heat welding type. It’s often used for heavy instrument repairs for this reason. It is an efficient procedure that doesn’t create much waste. Since there is no need for external gas, it is also low-cost. There will be a bit of slag left over, however, and it will require a bit of cleanup to make a beautifully finished weld.

3. Stick Shielded-Metal Arc Welding (SMAW)   

This procedure of welding started in the 1930s but continues to be efficient and upgraded today. It has remained a popular kind of welding because it is simple and easy to learn, as well as low cost to function. Though, it doesn’t create the neatest welds, since it splatters easily. Cleanup is typically necessary

A useable electrode “stick” also serves the role of filler metal. An arc is produced that connects the end of the stick to the base metals, melting the electrode into filler metal and producing the weld. The stick is coated in flux which creates a gas cloud when heated up and protects the metal from crossing. As it cools, the gas settled on the metal and becomes slag.

Since it didn’t require gas, this procedure can be used outdoors, even in opposing weather such as rain and wind. It also works well on corroded, painted, and dirty surfaces, making it great for instrument repairs. Different types of electrodes are available and easy to swap, making it simple to weld metals of many different types, though it’s not great for thin metals. Stick welding is a highly skilled procedure with a long learning curve

4. MIG Gas Metal Arc Welding (GMAW)   

MIG welding is a simple form of welding that can easily be completed by new welders. MIG stands for metal inert gas, however, it is sometimes so-called gas metal arc welding (GMAW). It is a quick procedure that involves the filler metal being fed through the wand, while gas is expelled around it to shield it from external elements. This means it’s not great for external use. Still, it’s a versatile procedure and can be used to weld many different kinds of metal at different thicknesses.

The filler metal is a useable wire fed from a spool, and it acts as an electrode as well. When the arc is produced from the tip of the wire to the base metal, the wire melts, becoming filler metal and producing the weld. The wire is continuously fed through the wand, allowing you to dial in your favored speed. Done correctly, MIG welding creates a smooth and tight weld that is visually appealing.

5. Laser Beam Welding     

This kind of welding can be used on metals or thermoplastics. As the name implies, it includes the use of a laser as a heat source to produce the welds. It can be used on carbon steel, stainless steel, HSLA steel, titanium, and aluminum. It is easily automated with robotics and is therefore used regularly in manufacturing, such as in the automotive industry.

6. Electron Beam Welding    

This is a kind of welding where a high-velocity beam of electrons produced heat through kinetic energy, welding two materials together. This is a highly sophisticated form of welding that is completed by machines, generally in a vacuum.

7. Plasma Arc Welding     

Plasma arc welding is similar to GTAW, but it used a smaller arc, growing the precision of the weld. It also uses a different torch, doing much higher temperatures. Gas is pressurized inside the wand, creating plasma. The plasma is before ionized, making it electrically conductive. This allows the arc to be created, producing incredibly high temperatures that can melt the base metals. This allows plasma arc welding to be completed with no filler metal, another similarity to TIG welding.

This kind of welding allows deep weld penetration with narrow welds, creating aesthetically pleasing welds, as well as a high level of strength. On top of this, high welding speeds are also possible.

8. Atomic Hydrogen Welding

Atomic hydrogen welding is an extremely high-heat form of welding when used to be known as arc-atom welding. This kind of welding involves using hydrogen gas to shield two electrodes complete with tungsten. It can reach temperatures above those of an acetylene torch and can be completed with or without a filler metal. This is an older form of welding that has been exchanged by MIG welding in recent years.

9. Electro slag

This is an advanced procedure of welding that is used to join the thin edge of two metal plates together vertically. Instead of the weld being applied to the outdoor joint, it will take place between the edges of the two plates. A copper electrode wire is fed through a useable metal guide tube that will act as filler metal. That electricity is introduced, the arc is produced, and a weld begins at the bottom of the seam and is slowly moved up, producing the weld in place of the seam as it goes. This is an automated process and is completed by machine.

Conclusion

Hopefully, you now have a basic understanding of the different kinds of welding. Some kinds are performed by a machine and require expensive specialty instruments. Others can be completed by a hobbyist at home without breaking the bank. If you’re looking to purchase a welder, be sure to check out one of our guides equating the best welders for home use.