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Common Welding Techniques Explained
Welding is one of the oldest but most resilient and strongest metal joining processes, widely used by industries worldwide. At its core, the goal of welding is to fuse two pieces and form an everlasting bond. However, you can use dozens of welding techniques to achieve that goal.
That's why we decided to explain the foundations of the most common welding techniques.
This article covers the four most popular methods of MIG, TIG, Stick, or Flux-cored Arc welding, and advanced welding processes such as Laser welding or Resistance welding. So buckle up!
Aluminum Fuel Cell TIG Welding Repair
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Types of Welding Processes
Welding is a fantastic metal joining procedure, but as with any profession, it is evolving. As a result, we can use over a dozen different types of welding. We can group the basic types of welding processes based on the heat source used to melt and fuse the pieces.
Types of Welding Processes
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Based on the source of the heat used to melt and fuse pieces, different welding processes are:
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Arc welding processes
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Resistance welding
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Gas Welding
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Solid state welding
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Other welding processes
In this article, we'll focus more on arc welding techniques since you are likely to use them at home. Nonetheless, we will also discuss some amazing, highly specialized joining techniques.
Welding a weight tree with two barbell holders for a home gym.
Photo by @ironroots_rc (TikTok)
Arc Welding Techniques and Processes Explained
Arc welding techniques use the heat of a welding arc to melt and fuse the pieces, and you probably guessed that by its name. The arc appears once you close the circuit between the electrode and the grounded base metal, both of which you connect to the positive and negative terminals.
The arc's heat reaches extreme temperatures between 6,500 and 10,000 degrees F. This heat melts the two pieces into the joint and electrode or filler metal.
Depending on whether the electrode is also a filler metal that melts during the welding process, we can further group arc welding techniques into:
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Consumable electrode welding techniques: Processes such as MIG welding, Stick welding, or Submerged arc welding use consumable electrodes. The heat of the arc melts the pieces and the electrode or filler metal that fills the welding joint.
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Non-consumable electrode welding techniques: Processes such as TIG welding, Electroslag welding, or Carbon arc welding use non-consumable electrodes. The electrodes form an arc and withstand heat without melting.
Consumable Electrode vs Non-consumable Electrode
To make this article more straightforward for beginners, we will divide arc welding processes based on their use in home welding. As a result, we'll discuss the four most common arc welding techniques and other less common techniques for you as a hobby or DIY welder.
DIY Welding Projects with Stick Welding
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4 Most Common Arc Welding Techniques
The four most common welding techniques are:
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MIG welding
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Stick welding
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TIG welding
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Flux-cored arc welding
If you browsed the internet or the welding machine market, you probably came across some of these terms. Now, it is time to explain them further.
4 Basic Types of Arc Welding
Gas Metal Arc Welding GMAW, or MIG welding
Gas Metal Arc Welding, or simply MIG (Metal Inert Gas) welding, is an arc welding process that uses a continuously fed filler wire electrode. The machine uses the wire both as filler and electrode, and it is consumed during the process, making MIG a consumable arc welding technique.
MIG welding is, without a doubt, the most popular welding process among beginners, and there is a reason for this. Beginners consider GMAW to be the most straightforward to master and use. The automatically fed welding wire allows you to use both hands and concentrate on the joint.
As you move the MIG welding gun across the joint, you create a weld pool of molten consumable wire and base metal. This puddle can react with atmospheric gases and pick up the contamination, so you need an external gas supply. MIG welding typically uses a mixture of Argon and CO2 to protect the puddle.
MIG Welding Process
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Check out our article to learn how to MIG weld.
Applications And Advantages Of Gas Metal Arc Welding Process
MIG welding is highly suitable for mild steel or low-carbon steel plates, but you can also weld aluminum and stainless steel. GMAW does well with medium and thin metal plates, which makes it highly versatile in automotive industries, general construction, DIY, hobby, and home applications.
Beginners love the MIG welding process due to its ease of use. Today, welders such as YesWelder MIG205 DS have synergic options, where you just input the material type and wire thickness, and the machine automatically adjusts the parameters.
Nonetheless, welders use MIG welding throughout various industries. Industry-grade MIG welders use an advanced welding process that allows you to control all the parameters and outcomes of welding. A high level of control also includes MIG in welding automation.
Shielded Metal Arc Welding (SMAW) or Stick Welding
The Shielded Metal Arc Welding process, commonly known as Stick welding, is one of the industry's favorites. This quick and cheap welding process produces strong welds, and that's what matters the most in large-scale industrial applications.
Stick Welding in Action
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Stick welding is one of the oldest welding processes. It uses a self-shielded electrode. The electrode contains a layer of flux that melts during the process and creates a layer of slag on top of the weld. The slag protects the molten weld zone from contamination, so you don't need external shielding gas protection.
Be aware that the electric arc of an SMAW reaches high temperatures. This heat allows welders to weld medium and thick stock with ease, but remember welding safety. You must wear thick PPE, including leather gloves, a welding helmet, and a leather jacket.
Stick welding uses simple, compact power sources known as Stick welders. Stick welders, such as YesWelder Arc 205 Pro, are small and straightforward. Welders are easy to use and portable, weighing approximately 10 lbs, so you can carry them around for your work.
Learn how to Stick weld in our comprehensive article.
Applications and Advantages of Stick Welding Technique
As noted, low costs and high welding speeds make Stick welding a widely used technique in steel construction and industrial fabrication. Welders use it to weld iron and steel, and very often in the pipe welding process. The ability to weld without shielding gas makes Stick welding highly useful in outdoor applications, field jobs, and repairs.
Stick is best suited to joining carbon steel, alloyed steel, stainless steel, cast iron, and ductile iron. However, electrodes are also available for non-ferrous metals such as aluminum, nickel, or copper alloys. Nonetheless, welders prefer other welding techniques for non-ferrous metals.
Stick/Arc welding is a manual welding method, which makes it more challenging than MIG. Welders also call it Manual Metal Arc welding or MMA welding. That means you manually control all the parameters, including welding speed, arc length, travel, and work angles. Some also refer to Stick as Arc welding since it is a pioneer of all Arc welding processes.
Stick Welding for Farm Repairs
Source: https://www.youtube.com/shorts/KZW7XIbnGZI
Gas Tungsten Arc Welding (GTAW) or TIG Welding
Gas Tungsten Arc Welding, or TIG welding, is one of the most complex welding methods, but it yields the highest-quality results. GTAW uses a non-consumable tungsten electrode to create an electric arc and melt the pieces.
Tungsten has the highest melting point of any metal, so it can withstand extreme temperatures without melting and consuming. However, pure tungsten doesn't produce the best results, so most new electrodes use added elements.
TIG Welding with Filler Rod
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You can use TIG (Tungsten Inert Gas) as an autogenous or fusion process or with a separate TIG filler rod. When welding thin gauge metals, the heat of an arc is enough to melt and fuse two pieces without a gap. However, as the thickness increases, you will need TIG welding rods. You should choose the filler material according to the thickness and type of metal you are welding.
Gas tungsten arc welding GTAW also requires shielding gas protection, but compared to MIG, it must be a high-purity, inert gas such as Argon. Gases such as CO2 or oxygen can contaminate the tungsten electrode and weld pool, so an inert gas is a must-have for TIG.
TIG Welding with Pure Argon
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Check out TIG welding tips and tricks for successful welding.
Applications and Advantages of Gas Tungsten Arc Welding
With its excellent heat control, precision, and quality, TIG is a preferred method in all applications that include welding delicate, thin, exotic, or non-ferrous metals.
TIG produces high-quality welds that meet the requirements of industries such as aerospace, nuclear, or food and beverage. Nevertheless, you can use GTAW in your home applications when welding aluminum or steel.
TIG Welding in the Aerospace Industry
https://weldingpros.net/tig-welding-in-aerospace-industry/
Skill-wise, GTAW is the most challenging home method to master. This type of welding is another manual process in which you manually control all the critical parameters. You wield the welding torch in one and the rod in the other hand, so getting the right dab and move rhythm can be hard for many beginners.
Also, keep in mind that TIG welding equipment can be pricey, but you don't have to break the bank with the YesWelder TIG 200 AC/DC welder.
Flux Cored Arc Welding (FCAW)
Flux-cored Arc Welding, or simply Flux core welding, is a semi-automated welding process that combines the ease of use of MIG with the ability to weld outside like with MMA welding. Like MIG, the power supply automatically feeds the wire. However, similar to stick electrodes, the self-shielded wire is filled with flux.
Flux core welding uses equipment and weld technology similar to MIG but with different rolls and polarity. The welder automatically feeds the flux-cored wire. As the wire melts, so does the flux, forming the slag. Slag protects the molten metal from atmospheric contamination, so you don't need a shielding gas.
How Does Flux-Cored Arc Welding Work?
Source: https://www.lincolntech.edu/
Applications and Advantages
As we mentioned, flux-cored arc welding uses the same equipment as MIG. Therefore, most MIG welders also support FCAW, but there are small machines such as YesWelder Flux 135.
YesWelder Flux-135-PRO 110V Gasless MIG Welder
Nonetheless, we can discuss advantages and applications. As noted, FCAW combines the good sides of Stick and MIG, so welders often use it for easy and quick outdoor repairs. Welders also use FCAW for general fabrication, farm and ranch maintenance and repairs, and home applications.
Flux Core Welding Outdoors
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Other Arc Welding Processes
Besides the most popular four, there are also arc welding processes that are best suited for advanced applications and specific industries. The remaining methods that use the heat of an arc are:
Plasma Arc Welding (PAW): Plasma welding is an advanced process based on GTAW principles. Electrical current passes through an orifice of the nozzle with a tungsten electrode protected by gases. Once electricity passes through pressurized gases, they form plasma and produce a narrow bead, pleasing weld. The method produces extremely high-temperature, strong, and precise welds.
Plasma Arc Welding Process
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Atomic hydrogen welding (AHW or Athydo): This is an arc welding process that uses the heat of an arc that forms between two tungsten electrodes. Welding occurs in a shielding atmosphere of hydrogen. This highly specialized welding technology produces high temperatures and precise, high-quality welds, but due to its high costs, regular arc welding methods replace it today.
Submerged Arc Welding (SAW): This is a unique technique compared to other processes. As the name states, the arc is submerged under a blanket of flux, and the entire process is automated or semi-automated. Since the arc is not exposed, there is lower exposure to radiation and heat.
Submerged Arc Welding Process
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Electroslag Welding Process (ESW): a single-pass welding process welders usually use when joining thick materials in a vertical or near-vertical position. The arc generates heat that initially melts the filler metal and weld metal in the joint. The arc then extinguishes, and the molten slag, which is conductive, provides heat to melt the filler metal and base metal.
Carbon Arc Welding (CAW) is the oldest welding method, similar to SMAW. However, unlike SMAW, CAW uses non-consumable carbon electrodes. The electrode heats and fuses the pieces, but welders rarely use this method today.
Carbon Arc Welding Process
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Resistance Welding Techniques
In the resistance welding technology, the electrical resistance of the materials creates the heat required to melt and fuse the pieces. Once the electrical current meets the resistance of two pieces, it generates intense heat used to join metals.
These techniques are generally safer than Arc welding since an electric arc causes no radiation, burns, or intense heat. However, the applications are limited to materials with high electrical resistance and low thermal conductivity.
Resistance Welding Principle
Source: https://avioweld.com/
Types of Resistance Welding
Welders use quite a few resistance-joining techniques today. Most commonly, those are:
Spot welding: This method uses two copper electrodes that conduct the current through two pieces of metal, joined without a gap. The resistance melts the pieces, and the pressure of copper tongs creates spot-like welds called nuggets.
Projection welding: A technique that uses embossing (projections) to concentrate the current and welding force on a small area. This welding process has various competitive advantages because it ensures quality results at low costs.
Seam welding: Resistance seam welding is a variation of resistance spot welding. The heat from the disc-shaped electrode wheels creates a continuous weld across the seam as the workpieces are fed between them. This action results in a rolling resistance weld or a non-hermetic seam weld.
Flash butt welding: Another electrical resistance welding process used for joining two pieces. The resistance of the parts provides energy transfer and heat suitable for metal welding. The components are positioned end-to-end across the entire joint area.
Gas Welding Technology
In gas welding techniques, the combination of gases provides the heat required to melt and fuse the pieces. Gas welding is also one of the oldest methods, primarily used before scientists developed coated electrodes.
What is Gas Welding?
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While there are various combinations of gases, welders typically use oxygen and acetylene. One is flammable gas (fuel), and the second is oxygen. This mixture forms the oxyacetylene welding method, and the industry loves it due to its high welding speed and low costs. Metal fabricators also use it for cutting.
Other gas welding techniques include oxy-hydrogen welding, propane brazing, or air-acetylene welding. Some fabricators also use Liquefied Petroleum Gas (LPG) for cutting since it creates an oxidizing atmosphere that is unsuitable for welding.
Use Liquefied Petroleum Gas (LPG) for Cutting
Source: https://www.supergas.com/
Solid State Welding
Solid-state welding methods use temperature and pressure over time, either individually or in combination, to join the materials without melting. The process can last for a millisecond or even take several hours to complete, but this has its benefits.
Since you are not reaching the melting point of the pieces, you don't need to worry about the conductivity and thermal expansion of the materials. Additionally, welded pieces retain their original thermal and metallurgical properties.
Types of Solid-State Welding Processes
There are several types of solid-state welding techniques. Some of them use recent breakthroughs, but welders have been using some for years and ages. Common solid-state welding processes are:
Most Common Techniques of Solid-state Welding (SSW)
Source: https://www.mdpi.com/
Cold Welding: This method uses pressure at room temperature to join welding metals. The pressure creates a joint on material contact, but this can cause deformation at the weld. Welders join thin materials using hand tools, but thicker materials require a greater pressure that produces a press.
Friction Welding joins materials through the heat produced by friction. Friction is caused by rubbing welding material surfaces under pressure. Machines rotate one workpiece against another to create frictional heat. Once friction creates the desired temperature, the movement ceases, and extra pressure is applied.
Friction Welding Process
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Diffusion Welding: Diffusion welding uses a combination of temperature and pressure to join the welding materials. The diffusion of the interface atoms creates the bond between both weld pieces. The surfaces are heated to below the melting temperature.
Explosion Welding: In this technique, parts are joined at a high velocity using a controlled detonation. The shockwave of impact and the energy expended by the collision produce heat, which melts and fuses the metal at the interface during welding.
Explosion Welding Process
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Forge Welding: One of the oldest metal joining methods. It works by heating metals in a forge before applying pressure (or hammer blows). Blacksmiths hammer the molten metal to cause a permanent deformation at the weld interface or to join the two pieces together.
Ultrasonic Welding: Ultrasonic welding uses local high-frequency vibratory energy to join parts held together under pressure. An ultrasonic tip or electrode is clamped against the workpieces. As it oscillates parallel to the weld interface, the energy and pressure make the pieces fuse.
Ultrasonic Welding Process
Source: https://www.tws.edu/
Other Advanced Welding Methods
In the end, we left the advanced welding types that are used in highly specialized conditions or with equipment that requires a trained welding technician to operate. Here are some of the examples:
Thermite welding: Thermite welding, or exothermic welding, is a specialized fusion welding process. This unique technique utilizes chemical reactions between a mixture of metal oxide and a reducing agent. The chemical reactions generate an intense exothermic reaction, which produces molten metal that effectively fills the joint between the workpieces.
Thermite Welding Railroad Rails
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Electron beam welding (EBW) is a fusion welding process in which an electron gun generates accelerated electrons. This high-speed stream of electrons is tightly focused using magnetic fields and shot onto the weld materials. The beam of electrons creates kinetic heat as it impacts the workpieces, causing them to melt and bond together.
Laser welding: Laser beam welding (LBW) is an advanced welding method that uses a laser as a heat source to melt and fuse the pieces. The laser is tightly concentrated into the weld joint, producing an extremely precise weld zone. Different types of welding lasers produce different heat, but they typically fall short when you need to weld thicker metals. That's why welders use hybrid laser beam welding methods that combine laser beam welding with regular arc welding techniques.
Laser Beam Welding Process
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🧐Common Welding Techniques Explained FAQ
1. What are the main types of welding processes?
Welding processes can be grouped based on the heat source used to melt and fuse metal pieces. The main types include:
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Arc welding processes
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Resistance welding
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Gas welding
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Solid-state welding
-
Other welding processes
2. What are the types of arc welding processes?
Arc welding includes common types like MIG, TIG, Stick, and Flux-cored, as well as advanced types such as Plasma Arc (PAW), Atomic Hydrogen (AHW), Submerged Arc (SAW), and Electroslag Welding (ESW).
👏 You may be interested in the following:
- How To Choose The Right Welding Types
- Tips For Properly Prepping Metal For Welding
- How To Choose the Right Gas For Welding Different Metals
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