A Brief Guide to Different Welding Processes

26 March 2020

It is easy to be overwhelmed by the multiple information presented on the different welding processes. However, it can be difficult to start such without knowing anything about it. Welding processes, in itself, are complicated enough without prior knowledge about its types. Some types are performed by machine and require expensive specialty equipment. Others can be performed at home without breaking the bank. Below is a brief guide to different welding processes.

Metal Inert Gas (MIG) Welding 

Metal Inert Gas (MIG) welding is a simple form of welding that can easily be performed by new welders. MIG stands for metal inert gas, though it is sometimes called gas metal arc welding (GMAW). It is a quick process that involves the filler metal being fed through the wand, while gas is expelled around it to shield it from outside elements. This means it’s not great for outdoor use. Still, it’s a versatile process and can be used to weld many different types of metal at different thicknesses.

The filler metal is a consumable wire fed from a spool, and it acts as the electrode as well. When the arc is created from the tip of the wire to the base metal, the wire melts, becoming filler metal and creating the weld. The wire is continuously fed through the wand, allowing you to dial in your preferred speed. If done correctly, MIG welding produces a smooth and tight weld that is visually appealing.

Tungsten Inert Gas (TIG) Welding

Tungsten Inert Gas (TIG) welding, otherwise known as Heliarc or gas tungsten arc welding, is a type of welding wherein the electrode is non- consumable and composed mainly of tungsten. It is one of the few types 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 desire, but you will have to feed it by hand. A gas tank is necessary with TIG welding to provide the constant flow of gas needed to protect the weld. This means it’s generally better performed indoors and away from the elements.

Shielded-Metal Arc Welding

Shielded metal arc welding, otherwise known as stick welding, has remained a popular form of welding because it is simple and easy to learn, as well as low cost to operate. However, it doesn’t create the neatest welds, since it splatters easily. Cleanup is usually necessary.

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

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

Laser Beam Welding

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

Electron-Beam Welding

This is a type of welding where a high-velocity beam of electrons creates heat through kinetic energy, welding two materials together. This is a highly sophisticated form of welding that is performed by machine, generally in a vacuum.

By contacting our welding maintenance and repair experts at Sureweld Engineering located in Hastings, Victoria, we can guarantee that you obtain prompt and highly efficient professional onsite repair services for your trucks or heavy machinery, thus reducing the possibility of weld defects.