5 Types of Welding Processes with Diagram and their Usage

Types of Welding Processes

Today we find ourselves in a particular era in which technology and professionalism marry in a truly surprising unicum, in all work areas, so that great results can always be obtained with the least expenditure of effort and energy and the highest standards of professionalism. One of these areas is welding.

But what do we know about welding? What are the main methods, products, and techniques to deal with? Here are some main indications from this point of view.

Different Types of Welding  Process (with Diagram) and General Definitions

There are myriad types of welding and many procedural paths to keep in mind in this work environment. We must first consider that the quality of each weld is respected when all the procedures and procedural specifications are followed in a well-defined process and are carried out by experienced, qualified personnel able to work in safe conditions.

When it comes to welding, then we obviously distinguish that the techniques used, are very different from each other. Generally speaking, a particular expert in the field usually prefers:

  • so-called pulsed MIG-MAG robotic welding
  • robotic welding with TIG and TIG with AC and DC cold wire.

But what are they? Here are the definitions, specifications and used methods of the welding process.

Different Types of Welding  Process

5 Common Types of Welding Processes

There are some of the most common types of welding processes including;

  1. TIG Welding (GTAW)
  2. MIG Welding (GMAW)
  3. Laser Beam Welding
  4. Shielded Metal Arc Welding
  5. Flux Cored Arc Welding (FCAW)

TIG – TIG Welding: What it is, How it is Work

TIG welding is used mainly in the aerospace sector. However, it is also used in other fields such as automotive, electronics and glass manufacturing.

TIG welding is not a technology that needs much explanation to the reader – it is extremely simple to understand and can be fully mastered by anybody with some basic skills in welding.

This text will provide you with the basics of how a TIG weld works, what are its main use cases, who does it and how it works.
TIG Welding

According to some interpretations it is, unlike other systems, a somewhat more expensive practice, but this is due to the machines used and the gases used. However, on the other hand, it must also be said that in principle it is also a very precise and detailed operation, useful not only, as anticipated, for thin thicknesses, but also for valuable and valuable materials and high-level constructions.

From this point of view, however, it should be remembered once again, as if it were a sort of indispensable mantra, that this practice, as well as others, requires knowledge and professionalism that is, to say the least marked and verifiable, and a meticulous preparation as to the joint to be welded. This is why it is always necessary to rely on expert hands.

When Tig Welding Used

When Tig welding is used in the fabrication and repair of aluminum parts, it produces a weld that is significantly stronger than a TIG weld made on steel. This is because the heat input is lower when welding aluminum, so the metal does not melt as quickly. The lack of melting also results in a smaller weld pool, which leads to less distortion of the base metal.

MIG – MAG Wire Welding: What it is, how it is work

When we talk about wire welding ( MIG-MAG), we are talking about a welding realization also called continuous wire which is chosen for particular and specific operations. In detail this welding is basic and required for parts and components that require a high level mechanical seal and large amounts of metal use.

Also in this case we are talking about a technique that requires a joint with adequate preparation, even if it is also fine for operations that do not require detailed precision. And, in addition, compared to TIG operations, this instead boasts lower costs.

MAG Wire Welding

When MIG Welding Used

MIG welding is a versatile welding process that can be used for many applications. The process is often used for welding thin metals, such as sheet metal and aluminum. MIG welding can also be used for welding thicker metals, but the welds may not be as strong as welds made with other welding processes. This a good choice for welding in tight spaces and for welding thin metals that are difficult to weld with other processes.

Laser Beam Welding: What is it and How it is Works

Laser Beam Welding is a welding process that uses a laser as the heat source. It can be used on metals or thermoplastics. The laser beam is directed at the weld joint, and the heat from the laser melts the material. The molten material is then pressed together to create the weld. Laser beam welding is a very precise process, and it can be used to create very small welds.

Laser Beam Welding

When Laser Welding Used

When laser welding is used, the weld seam is narrower and higher in quality than when other welding processes are used. Lasers produce a very focused beam of heat, which allows for a more controlled weld. The heat from the laser also causes less distortion to the surrounding material, which results in a stronger weld.

Shielded Metal Arc Welding (Stick Welding): What is it and How it is Works

Shielded metal arc welding, or stick welding, is a process that uses an electric arc to join metals together. The welder uses a flux-coated rod to create the arc, and the molten weld puddle is drawn out with the electrode. 

Stick welding is a popular welding process because it is relatively easy to learn and it can be used to weld a variety of metals, including low and high carbon steel, stainless steel, and aluminum. The process produces strong welds that are resistant to cracking and breaking. 

One downside of stick welding is that it can be difficult to produce consistent results, especially when welding thicker metals. In addition, the fumes from the flux can be dangerous, so proper ventilation is essential.

Shielded Metal Arc Welding

When Sheilded Metal Arc Welding Used

When shielded metal arc welding is used, a flux-coated electrode is used to produce the weld. This type of welding is also called stick welding. The flux protects the electrode and the weld from contamination. Shielded metal arc welding is a very versatile type of welding and can be used to weld a variety of metals. It can be used to weld thin sheet metal and it can also be used to weld thick plates of metal.

Flux Cored Arc Welding: What is it and How it is Work

Arc welding is a process that uses an electric arc to weld metals together. This is done by creating an electric current between two electrodes—the welding electrode and the workpiece. When the current passes through the air, it creates an arc of electricity. This arc provides the heat necessary to weld the metals together.

There are several different types of arc welding, including shielded metal arc welding (SMAW), gas tungsten arc welding (GTAW), and flux-cored arc welding (FCAW). FCAW is a type ofarc welding that uses a tubular wire filled with flux as the electrode. The flux protects the weld from contamination and helps to stabilize the arc. FCAW is a popular choice for welding mild steel, stainless steel, and aluminum.

Flux Cored Arc Welding

When Flux Cored Arc Welding Used

Arc welding is a process that joins metals by heating them with an electric arc. The arc is created between the workpiece and a consumable electrode. Flux-cored arc welding (FCAW) is a type of arc welding that uses a tubular electrode filled with flux. The flux protects the weld puddle from atmospheric contamination and helps to stabilize the arc. FCAW can be used to weld many different metals, including carbon steel, stainless steel, and aluminum.

Projection Welding Differences with the Different Condensing Systems

Then we have the so-called  spot welding , otherwise called, more generally projection welding. Projection welding is a welding technique particularly used in the field of processing some elements in detail such as sheets and thin wires (nets, trolleys, handles), also because it is possible to automate and is also a specific technical low cost and rather cheap.

Compared to this technique, however condenser or capacitive discharge welding is a technique that allows you to have a high and specific level welding ‘in your hands’, usually chosen to bond a sheet metal to a stud) threaded structures, pins, pins, fastons). This technique is chosen to carry out welding of thin sheets, for which, among other things, the aesthetic aspect is of great importance, at least on a par with that of functionality.

Difference Between Welding and Brazing

Very often newbies or those who are not experts in the sector tend to confuse two procedures, two techniques that really should not be combined, or at least not in this context. Let’s talk about  welding and  brazing.

But welding and brazing are different processes through which a lasting union can be achieved over time, obtaining the continuity of the materials that are connected, even if through different paths. Which?

In particular, to make a weld, as the experts in the sector who work in this branch say and know very well, a real localized fusion of the components of the pieces to be joined is carried out, with or without the addition of filler material.

We speak of brazing or specifically, even more, of brazing then when the base material is not melted but just heated and the process of joining the materials is carried out to melt only the filler material, which has a temperature of fusion reduced to that of the base material.

What can be Welded: Elements and Clarifications

As the specialists in the sector explain, in the current state of things material is considered potentially weldable when it lends itself to the creation of a structure in which continuity is ensured and which has the characteristics that fall within the required quality requirements.

There are several elements to consider when welding. This is because the welding process compares one or more types of materials, which must primarily meet two requirements: the base material, i.e. the material that represents the pieces to be welded, should be the same for both pieces (and in this case we speak of homogeneous welding), or it can also be different (and in this situation precisely we speak of heterogeneous welding).

But the metallic materials that come more generally are steel, aluminum alloys, nickel alloys and titanium alloys. The only polymeric materials that are welded, on the other hand, are thermoplastic ones.

Watch out for the filler material, which is the material that is inserted in the form of rods, threads or ribbons and placed in the molten state between the edges to be joined. The filler materials are always particularly pure, so imperfections within the fused area of ​​a joint generally derive from the base material.

Parameters for Welding

When it is necessary to weld, it is then necessary to respect some constraints. Or rather, welding is based on the necessary compliance with some specific parameters for each type of process. Generally speaking, there are in principle two main characteristic parameters:

specific power, which indicates the thermal power supplied per unit of the surface of base material, and is measured in W / cm2; and the welding speed, which indicates the speed of the heat source, measured in cm/min.

There are, it is good to say it and have it clear in mind, always risks and dangers as such in the very nature of this type of operation. Welding itself, working on certain types of materials, if carried out by inexperienced personnel, can produce unpleasant consequences. This is why it must be done with experts.


In conclusion, there are many types of welding processes that can be used, depending on the materials that need to be joined and the desired outcome. Some of the most common welding processes are described above, but there are many other options available. If you are considering having a piece of metal welded, be sure to discuss the options with a professional welder so you can choose the best process for your project.

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