Last Updated On:
As of now, there are quite a few welding processes and types of welding. Understanding the differences between these welding processes is crucial if you want to choose the correct one for you.
This welder types comparison guide will reveal the different welding types and there uses.
Some of them are very rudimentary, but some of them are very advanced. These welding techniques differ from relatively simple, to extremely complicated, so it's important you decide which type is right for you.
However, for somebody working in a chop shop or looking to so some welding at home, there are four standard welding processes you need to know about: TIG, MIG, Stick and Arc Welding.
(Check out our review on the best multi process welder that combines them all!)
The best type of welding depends on exactly what you want to achieve and in this guide we'll go through the four standard types.
Our little guide will take you through all the welding processes including the four major of the welding types. We'll even go over mig vs tig welding.
So, without further ado, let’s get going!
These are the main 4 types of welding techniques. Keep reading below for more info regarding the welding processes and detailed information about each welding type.
Gas Metal Arc Welding (GMAW), most commonly known as MIG welding , is the process of continuously feeding a line of electrodes through a specialized “gun”.
In the gas metal arc welding process the electrode forms an arc with the base metal you’re trying to weld and then melts, fusing the material together.
The entire MIG welding processes uses a protective gas bubble that protects the weld from the ambient air and the components within it.
It should also be said that, because a wire is being fed to the material, the pieces being welded together aren’t actually being fused, which provides you with the opportunity to weld different kinds of metals together.
Naturally, because the MIG welder uses a “consumable” you will have to replace the electrode after some time. Also, the gas that forms the protective bubble needs to be replaced occasionally too.
So, what do you use the gas metal arc welding type of welding for?
It should be said that the MIG welding processes can be applied in various situations.
Quality machines have a wide power output range and a gauge that will let you adjust the power, allowing you to approach softer material without fear of burning through it.
At the same time they’re still powerful enough to weld thick steel pipes and provide a strong connection.
Is it the best type of welder? Let's first go through the advantage and disadvantages of each.
In this welder types comparison guide TIG welding is one of the more popular types of welding processes. Many people are interested in the tig vs arc welding debate.
TIG, Heliarc or GTAW (Gas Tungsten Arc Welding) is a welding process where a non-consumable tungsten electrode is used to heat up the material and melt it, creating a weld puddle.
Unlike GMAW, gas tungsten arc welding is produced from a single metal type, because there is no filler metal used for the weld. These Welding processes have highly evolved in recent years giving it more everday uses and making it easier for the avarage person.
However, you can add another rod to provide a filler material for you, so that the welding process can be applied to more materials or different metals at once.
Just like GMAW, these welding processes requires a gas bubble to protect the weld from contaminants. The gases used with TIG are usually helium or argon, whereas you would use carbon dioxide for MIG.
Because there is no feeding involved, there is no need to replace the electrode, only refill the gas tank. That is a big advantage for gas tungsten arc welding.
Similar to other types of welding processes, GTAW (or gas tungsten arc welding) can be applied to many materials.
However, the thickness range of this welding type is more limited.
Though you can weld both steel and aluminum with the same ease, the materials you will be welding are going to be thinner.
The tungsten rod is much thinner than a stick rod, allowing you to make more precise but much thinner welds.
It is very simplistic in how it works but produces exceptionally strong welds, and it can be used to weld the thickest of materials.
The way stick welding works is through a single electrode that also provides most of the welding material. The electrode gets heated, then melts, but the intense heat melts the workpiece and welds the two parts together. The rod is also coated in flux, which creates a shield around the weld, protecting it from contamination.
Stick welding uses a consumable rod, and this rod will need to be changed frequently as you continue to weld.
It's the way to go for thick materials, including cast iron - which can be tough or impossible for other welding types.
But when you want to have two pieces of thick metal fused together, and to make sure the weld is going to last, this is the way to go.
At last, we come to our final welding type, arc, or flux-cored, welding.
This welding type is very similar to other types of welding, for example MIG welding. They both use a consumable wire that is being constantly fed to the weld. However, this is where the two begin to differ.
In arc welding, the wire used has a flux core that immediately generates a gas shield around the weld, whereas you need an external gas supplement for MIG.
There is also something known as dual-shielded welding, which uses another external gas supply to form a second shield for an even more secure weld.
Naturally, since there is a consumable, you will have to replace it once in a while.
However, unlike MIG, you don’t need to refill a gas tank if you don’t intend to use dual-shielded arc welding.
When using flux-cored welding style, you will want to use it with heavier and thicker materials.
Flux-cored welding also creates more heath then types of welding and you will want to use it where there is enough base metal to withstand that much heat.
This type is primarily used for heavy steel construction and erection, heavy repairs and heavy machinery and other such equipment.
Both MIG and TIG welding use an electric arc to create the weld. However the one big difference between them both is the arc process.
MIG welding uses a feed wire that continuously moves through the gun to create a spark. This process melts and this is what forms the weld.
TIG welding, conversely, uses longer rods to combine two metals directly together.
To reiterate, our goal here is to reveal welder types comparison between the four standard types of welding. Although there are other welding types, (flux-cored arc welding, gas welding, Plasma Arc Welding & Laser Welding) these are the most popular four.
As we said, MIG is the most versatile and the easiest one to learn; TIG is the most aesthetically pleasing; stick and arc produce the strongest welds and can operate under less than desirable conditions.
We also discussed the best beginner’s welder and the type that produces the strongest weld.
After all of this, the choice is, of course, yours.
What is the best type of welding? Whether you want to start easy with an MIG welder, or you want to master game at the hardest difficulty with a TIG welder, you will go with the welder that interest you the most.
Hi, my name is Gregory! I have been welding practically all of my life and love it. As I have gotten older I have started to weld less and less, so in order to continue my love for welding I created this website. I like to write about my experiences and help you all become welders. I hope that you enjoy the site!