What Are the Different Types of Welding?

As mighty as it is, welding may seem surprisingly simple. But experts in the field will know that there are actually multiple ways to weld – and the technique you choose matters. 

Whilst sparks flying when you’re welding might look cool in the movies, in reality, it’s often a sign that you’re not doing a very good job, or that you’ve chosen the wrong welding technique for the task. So, if you’ve been wondering about the difference between a MIG welder and a TIG welder, or if you’re not sure how to separate your flux-corded welding from your plasma welding, we’re here to help you out. 

Let’s get stuck in… And don’t forget to pick up all your essential welding supplies right here at The Hosemaster before you go!

Which type of welding should you choose?

Before we take a closer look at how to choose the right type of welding for your project, let’s explore what some of the main different welding methods are and what types of projects they’re best suited for.

MIG welding

Metal inert gas (MIG) welding is a type of arc welding process, where heat is generated by an electric arc. To generate the high temperatures required, large amounts of electricity are used to make an arc between an electrode and the parent metal that’s being welding together.

With MIG welding, alongside the continuous solid wire electrode that’s fed through a welding gun, this method uses a shielding gas (which is usually an inert gas), which won’t go through any chemical change when it contacts other gases in the atmosphere. This protects your weld from reactions and defects which can weaken the join.

Note: MIG welding is sometimes also referred to as Gas Metal Arc Welding (GMAW) and is one of the easier welding techniques.

Advantages of MIG welding

One of the main advantages of MIG welding is that it’s often faster than other techniques – because the wire is being continuously fed into the welding gun, there’s less need for stopping and starting throughout the process.

MIG welding is versatile and reliable, and can weld a wide range of materials safely and to a consistent standard. Plus, by varying the current, you can change the weld penetration for smooth, strong joins. MIG welders also produce less waste than other welding techniques. By continuously feeding your wire through the welder gun, you only use what you need (cutting down on any excess).

Lastly, this method is fairly easy to learn, which makes MIG welding more achievable for beginners, DIYers and hobby welders.

Disadvantages of MIG welding

Whilst MIG welding is quicker than other options, it’s not always as clean or precise as, say, TIG welding (see more below). Additionally, what you gain in speed you tend to lose in portability. MIG welders require a constant flow of shielding gas to work properly or you could develop weaknesses in the weld, so they need to be connected to a gas supply (which can reduce mobility).

The need for shielding gas, and lots of different parts, also makes MIG welders more expensive initially until you have what you need.

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TIG welding

Tungsten inert gas (TIG) welding – also known as Gas Tungsten Arc Welding (GTAW) – is another arc welding technique similar to MIG welding. However, a TIG welder uses the electric arc differently from a MIG welder. 

As we discussed above, MIG welding uses a feed wire that is continuously moving through the welding gun to create the necessary heat and spark to melt and seal the materials together. TIG welding, on the other hand, uses a fixed tungsten electrode and a hand-held welding rod to carry out the fusing process. Tungsten has a high melting point, which means that the arc generates more heat to melt both the parent metal and a filler metal to make the weld.

Advantages of TIG welding

First and foremost, TIG welds are strong, durable, and typically more resistant to corrosion and damage – which is vital for welding machinery, like cars and other automobiles. TIG welding is also incredibly versatile, and can be used to weld a variety of metals, including:

• Non-ferrous (non-iron-based) metals like aluminium and magnesium. 
• Dissimilar or delicate metals.
• Metals of differing thicknesses. 

TIG welding offers you a lot of control and precision, so you can tackle difficult welding areas (like curves, tricky shapes, and corners where you need more dexterity). As a plus, TIG welds are cleaner and neater, which is perfect on projects where your welds will be visible. This is because you can usually modify the heat via a foot pedal, which gives you more control over the weld bead and the appearance of the end result.

Disadvantages of TIG welding

The main disadvantage of TIG welding is its complexity. Between controlling the heat of the arc, keeping the shielding gas flowing, holding the filler metal in place, and ensuring all parts are a safe distance from each other, TIG welding is hard to learn, and should be left to professional and experienced welders. This complexity also means TIG welding is considerably slower than other welding techniques, and you need to be more meticulous about how you work to ensure a clean weld.

Top tip: TIG welding is difficult to master, yes, but the advantages make it well worth the time and effort.

As with MIG welders, TIG welders require a constant supply of shielding gas to work effectively. This reduces the portability, but also makes it difficult to use in non-controlled environments (for example, outdoor workshops that experience wind exposure).

Plasma arc welding

Plasma arc welding (PAW) is similar to TIG welding in terms of function – but PAW uses a much smaller arc and a much lower voltage. This is what is known as a ‘constricted plasma arc’ and allows for even more accuracy, control, and precision. The plasma is created through high pressures inside the welding gun, which concentrates a lot of heat at the tip – and requires plasma arc welding systems to use water cooling to regulate the temperature. 

Plasma arc welding is typically used to weld small components, like those needed by the medical and electronics industry.

Advantages of plasma arc welding

Due to the torch design, plasma arc welding allows for more precision and control, which is vital if you’re welding thinner materials or need to create a deep, narrow weld. Plasma arc welding is also frequently used on more difficult metals, like stainless steel and aluminium.

Alongside trickier metals, plasma arc welding is good for use with heat-sensitive materials. This is because you can use a low current mode, which reduces the voltage – and therefore the operating temperature. Plasma arc welding is fast, and can be used in a variety of positions, which makes it a versatile option.

Note: while this can be used by hand, most plasma arc welding is now used as part of an automated system.

Disadvantages of plasma arc welding

Plasma arc welding requires a lot of experience and expertise to use, which means it’s not a technique for beginners or inexperienced welders. In fact, because of the specialist nature you need to have proper training to use this welding method safely. It’s also very loud.

Plasma arc welding is expensive to set up, as it uses a lot of complex equipment to function – like the water cooling system.

Note: this equipment is also more delicate, and needs more maintenance to ensure it stays in good (and workable) condition.

Flux-cored welding

Flux-Cored Arc Welding (FCAW) is what’s known as a semi-automatic or automatic arc welding process. Developed as an alternative to stick welding, and similar to MIG welding in function, instead of using a solid wire electrode like a MIG welder would, flux-cored welding uses a wire tube filled with flux. 

Flux is a combination of chemicals, minerals, and alloying materials that prevent the molten weld metal from becoming contaminated by things like oxygen and nitrogen in the atmosphere.

It’s important to note that there are two different types of flux-cored welding:

• Self-Shielded Flux-Cored Arc Welding (FCAW-S): this uses an internal system to produce the gas needed for protection against contamination. This means no additional or external shielding gas is needed.
  
  
• Gas-Shielded Flux-Cored Arc Welding (FCAW-G): this requires an external shielding gas to be added for operation.

Note: the key difference is that FCAW-S is better for outdoor use, while FCAW-G is better for indoor or smaller environments.

Advantages of flux-cored welding

Due to its similarity with MIG welding, flux-cored welding is ideal for those who appreciate how MIG welding works, but needs something that can offer higher speeds and deeper penetration. Flux-cored welding has better arc stability, which allows you to use it at high speeds without compromising your weld quality.

It’s also a good option for those who regularly work with different types of metals – including varying thicknesses and alloys to create a strong and durable weld. Flux-cored welding requires less cleaning to make quality welds, which is perfect if you’re working with mildly rusted metals.

Top tip: FCAW-S can be more convenient, as it doesn’t need additional shielding – making it more portable.

Disadvantages of flux-cored welding

Unfortunately, flux-cored welding is renowned for producing more smoke and fumes than other techniques, which is important to bear in mind for health and safety reasons. This can also make it difficult for you to see the actual weld area, which could compromise the neatness of your weld.

Plus, if you don’t use flux-cored welding properly you could compromise the quality of your end result by:

• Introducing porosity into the weld, which can weaken it.
• Using incorrect filler wire, or inconsistently feeded the wire through the system, which can affect your weld.
• Incorrect handling and storage will impact your equipment in the long run, and potentially the quality of your work.

Top tip: FCAW tends to be more applicable to industrial or commercial use, as opposed to domestic or DIY use.

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Electron-beam and laser welding

Electron welding and laser welding are both types of power welding, which simply means they use electrical power to generate the heat required to melt and fuse materials together. 

Electron-beam welding uses a fine stream of electrons to generate heat energy, whilst laser welding uses concentrated beams of high-energy light that allow for highly defined accurate welds, and a flawless finish (when executed well).

Advantages of electron-beam and laser welding

Electron-beam and laser welding are both capable of handling a wide range of base materials, from delicate to more robust metals. This means they’re used across a variety of industries that need precision and control. These types of power welding are vital for accurate and precise welds, as the beam is narrow (which affords you more control over the weld).

Top tip: laser and electron-beam welding can even be used to join thermoplastics as they have small ‘heat-affected zones’ (how far the heat disperses outside of the weld).

Electron-beam welding in particular is incredibly useful when it comes to welding small areas, like those in more delicate or complex designs, because of the ability to focus the weld beam accurately.

Note: electron-beam welding is performed in a vacuum chamber, and is automated, not done by hand.

Disadvantages of electron-beam and laser welding

One of the main disadvantages to laser and electron-beam welding is that they’re expensive. Between the specialist components, and the computer technology, these types of welding aren’t suitable for beginners or hobbyists. Instead, you’ll find laser and electron-beam welding more commonly used in commercial, industrial, or scientific applications.

It’s worth noting that electron-beam welding and laser welding aren’t as effective on thick and dense materials as other welding methods are.

Choosing the right welding method for you

Now you’ve got a better idea about the main welding techniques, hopefully you’re feeling more confident about choosing the right one for your project. Below are some additional factors you should take into account when considering your options.

Material type and thickness

You should always let the types of materials you’re welding inform the weld method you choose to use, because some lend themselves to particular materials better than others.

For example, you’d want to use a TIG welder for non-iron based metals or those of differing thicknesses – whereas for more delicate or thinner metals, you’d need to consider using plasma arc welding methods.

Welding position

Whether it’s a flat surface, vertical, in a corner, on a curve, or anything else, the position you’ll be welding in might naturally steer you towards one method over another. 

Top tip: always remember to prioritise your safety and ease of use. Don’t make life harder or more dangerous for yourself by choosing the wrong type of welding method.

Speed and size

Some welding methods are quicker than others which allows you to complete the weld faster but also get through more welding at a pace – like with MIG welders, which are a faster option than some of the other methods.

If you have lots to do, you might prefer to opt for a method that offers more speed than precision (especially if the weld is hidden).

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Weld appearance

In some scenarios, the overall look of a weld doesn’t really matter, especially if the joined materials aren’t to be on show.

However, if you’re trying to achieve a polished finish, or if the cosmetic look of the weld is a priority, you’ll want to opt for a method that facilitates this. A TIG welder, for instance, might go for this approach because it enables them to achieve a cleaner weld and have precise control throughout the process – creating a neater and more professional end result.

Location

Consider where you’re going to be doing your welding because this will influence the type of method you choose. Flux-cored welding, for example, is a great choice if you need to weld outdoors because it doesn’t require a gas or electricity supply.

A MIG welder, on the other hand, might choose to work inside as it produces less weld slag (a byproduct of the process) and offers a much easier clear-up operation than other alternatives. 

Find essential welding supplies here at The Hosemaster

When it comes to welding, we’ve got you well covered – from hose sets, to individual fittings like double safety valves, and everything in between.

Hopefully you’re able to find everything you need on the website – but if you have any questions or need further guidance, please don’t hesitate to get in touch. Our customer service team is on hand and will be more than happy to help.

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