The Ultimate Guide to the Different Types of Welding

Choosing the right welding process shapes quality, cost, and production speed. This quick guide breaks down what each process does best, where it excels, and how to align it with your requirements. Professionals often know the big picture; this dives into the trade-offs that move projects forward. A smart selection avoids rework, controls distortion, and hits your target properties.

This article highlights the different types of welding in plain, technical terms so you can make confident decisions for prototypes, one-offs, or scaled production.

What Is Welding?

Welding joins metals through heat, pressure, or both, creating a metallurgical bond across a joint. Arc welding dominates industrial use, where an electric arc melts base metal and filler to form the weld. Shielding gases or fluxes protect the molten pool from atmospheric contamination.

Key variables influence results, including process type, filler chemistry, heat input, interpass temperature, and joint design. Codes and standards often apply, such as AWS D1.1 for structural steel or ASME Section IX for pressure components. Formal WPS and PQR documentation ensures repeatable, qualified procedures.

Great welds stem from many factors, but strong results are only possible when you select the right process for the application.

Common Types of Welding

Shielded Metal Arc Welding (SMAW)

SMAW, or stick welding, uses a flux-coated consumable electrode to create the arc and deposit filler metal. The flux layer forms shielding gases and slag during welding, protecting the pool and stabilizing the arc. Equipment remains simple and portable, making SMAW versatile in the field.

Operators appreciate its tolerance for less controlled environments. Wind and outdoor conditions impact other gas-shielded processes more than they do SMAW. Trade-offs include lower travel speeds and the need for slag removal between passes, which extends cycle time.

Common Applications of SMAW

Maintenance and repair work, structural steel erection, and field welding of pipelines often rely on SMAW. Cast iron repairs, thick base sections, and sites with limited power or access also benefit from its portability.

Gas Tungsten Arc Welding (GTAW)

GTAW, often called TIG, uses a non-consumable tungsten electrode with inert gas shielding, commonly argon or helium. The process delivers exceptional control over heat input and bead appearance. Welders can add filler manually or run autogenous welds on thin material.

Cleanliness is critical with GTAW, especially on stainless steel, aluminum, and titanium. AC balance settings enable oxide cleaning on aluminum, while pulsed current manages heat on thin sections. The trade-off is slower deposition and higher skill requirements.

Common Applications of GTAW

Aerospace components, sanitary process piping, and thin-walled tubing are frequent candidates for GTAW. Prototypes and precision assemblies in stainless steel, aluminum, Inconel, and titanium benefit from its accuracy and finish.

Gas Metal Arc Welding (GMAW)

GMAW, or MIG, feeds a consumable wire through a gun while shielding gas protects the arc. It supports multiple transfer modes, including short-circuit, globular, spray, and pulsed spray. Each mode controls heat input, penetration, and spatter levels.

Shops choose GMAW for speed, consistency, and easy automation. Wire feeders and robots deliver high throughput with minimal cleanup, especially in spray or pulsed modes. Wind sensitivity limits outdoor use unless enclosures or wind screens are present.

Common Applications of GMAW

Automotive fabrication, production lines, and general manufacturing use GMAW for sheet and medium-thickness steels. Robotic cells leverage its repeatability for brackets, frames, cabinets, and assemblies requiring consistent quality.

Flux-Cored Arc Welding (FCAW)

FCAW uses a tubular wire with a flux-filled core. Two variations exist: self-shielded, which needs no external gas, and gas-shielded, which combines flux with a shielding gas for improved properties. Both offer high deposition rates and strong penetration.

Self-shielded FCAW works well outdoors, handling wind better than GMAW. Gas-shielded FCAW excels in fabrication shops, balancing speed with robust mechanical properties. Slag removal and fume management remain important considerations.

Common Applications of FCAW

Structural steel fabrication, shipbuilding, and heavy equipment manufacturing leverage FCAW for thick materials and high productivity. Field work often favors self-shielded FCAW because portability and wind tolerance reduce setup time.

Submerged Arc Welding (SAW)

SAW buries the arc beneath a granular flux layer, eliminating arc glare and minimizing spatter. The process achieves very high deposition rates and deep penetration. Applications usually involve flat or horizontal positions on straight or circumferential seams.

Automation pairs naturally with SAW, supporting long, continuous welds on heavy sections. Setups include single- or multi-wire configurations for even higher productivity. Process constraints include limited positions and the need for flux handling.

Common Applications of SAW

Pressure vessels, wind towers, pipe mills, and bridge girders frequently use SAW. Long seams on thick plate benefit from its speed, low fume levels, and excellent mechanical properties.

Other Types of Welding

Electric Resistance Welding (ERW)

ERW joins materials by clamping components under pressure and passing current through the joint to generate heat. Spot and seam welding variants support sheet metal assemblies with fast cycle times and strong, repeatable nuggets. Automotive body-in-white is a prime example.

Laser Beam Welding (LBW)

LBW focuses a high-energy laser to produce narrow, deep welds with minimal distortion. Coupling with precise motion control enables clean, rapid joints on thin to moderate sections. High capital cost and tight fit-up requirements often come with the territory.

Plasma Arc Welding (PAW)

PAW constricts the arc through a nozzle, creating a stable, high-energy plasma column. The process bridges a gap between GTAW and LBW, offering excellent control for thin materials and high-quality seams.

Final Thoughts on Choosing the Right Welding Type

Smart selection reduces rework, stabilizes schedules, and protects margins. Materials, geometry, and code obligations narrow the field, while budget and takt time set the final direction. Teams that match process to purpose see fewer surprises and more consistent results.

A partner with real process depth can help weigh productivity against appearance, or deposition rate against distortion. Conversations should focus on joint design, fixturing, transfer mode, and fit-up tolerance. Clarity here leads to predictable outcomes on the floor.

This guide covered the different types of welding, the applications that suit them, and the trade-offs that matter when budgets and deadlines are real. Greenline Metals Inc. brings this approach to every engagement. We know projects benefit from practical recommendations, clear documentation, and a commitment to throughput and quality.

Need a custom metal fabricator in Toronto with proven welding expertise across materials and processes? Greenline Metals Inc. can evaluate your drawings, propose the right process, and execute to spec. Reach out to discuss timelines, certifications, and production volumes that fit your plan.