Different Types of Welding and How They’re Used
Welding is one of the foundational processes in manufacturing and construction. Whether it’s the creation of skyscrapers, bridges, automobiles, pipelines, or even delicate medical devices, welding plays a crucial role in joining materials together. It involves melting the base materials, usually metals or thermoplastics, and often adding a filler material to form a strong joint once cooled.
Understanding the different types of welding processes is essential for selecting the right one based on the application, materials, strength requirements, cost, and precision needed. In this guide, we’ll explore the most common welding types, how they work, their pros and cons, and where they’re commonly used.
How Welding Works?
Welding works by applying heat, pressure, or both to fuse materials. The energy source can vary depending on the welding method. It might be an electric arc, gas flame, laser, electron beam, friction, or ultrasonic vibration. Here are the basic steps of most welding operations:
- Preparation: The surfaces to be joined are cleaned and aligned.
- Welding: Heat is applied to the materials using the selected welding method.
- Filler Material (Optional): In many types of welding, a filler metal is added to strengthen the joint.
- Cooling: The molten material cools down and solidifies, forming a strong bond.
- Finishing: Excess weld material or slag is removed for a clean finish.
Each welding technique has different characteristics, advantages, limitations, and applications depending on the materials, thickness, position, and environment.
Different Types of Welding
Here are the common types of welding used in industrial processes throughout the world:
1. MIG Welding (Metal Inert Gas Welding)
MIG welding is one of the most commonly used and versatile welding processes in both industrial and personal projects. Developed in the 1940s for welding non-ferrous materials like aluminium and magnesium, it has since evolved into a staple for welding steel and other metals. It is a type of arc welding that feeds a continuous solid wire electrode through a welding gun into the weld pool, joining the base materials together.
At Kirmell, MIG welding is widely used in the fabrication of mild steel and aluminium welding components due to its high efficiency, clean welds, and suitability for large-scale production. Our engineers rely on this method for fabricating structural frames, machine parts, and sheet metal products where consistent weld quality and speed are critical.
Looking for clean, efficient welding on your next project? Get in touch with Kirmell or explore our MIG capabilities through our brochure.
How It Works:
The welding gun continuously feeds a consumable wire electrode and releases an inert gas (usually argon or a mix with CO₂) to shield the weld area. When the arc forms between the electrode and the workpiece, both the base material and the wire melt to form the weld.
Common Uses:
- Automotive manufacturing and bodywork
- Furniture and metal fabrication
- Home DIY projects
- Sheet metal welding
| Advantages | Limitations |
|---|---|
| Easy to learn and operate | Less suitable for outdoor use (wind affects shielding gas) |
| High welding speed and productivity | Not ideal for thick materials |
| Produces clean welds with minimal slag | Requires clean surfaces for quality welds |
2. TIG Welding (Tungsten Inert Gas Welding)
TIG welding is considered the most precise and aesthetically refined welding process available. Developed in the 1940s to meet the aerospace industry’s need for strong, high-integrity welds on thin materials like aluminium and magnesium, TIG is now used anywhere high-quality, detailed welds are essential. It uses a non-consumable tungsten electrode and a separate filler rod (if required), all shielded by an inert gas like argon.
How It Works:
An electric arc is created between a tungsten electrode and the base metal. An inert shielding gas (typically argon) protects the weld area. The welder may manually feed filler material when needed.
Common Uses:
- Aerospace components
- Automotive exhaust systems
- Stainless steel welding and non-ferrous metals like aluminium and magnesium
- Artistic metalwork and piping
| Advantages | Limitations |
|---|---|
| Very clean and aesthetically pleasing welds | Slower process compared to MIG |
| Excellent for thin or delicate materials | Requires high skill and control |
| No spatter or slag | More expensive equipment setup |
3. Stick Welding (SMAW – Shielded Metal Arc Welding)
Stick welding is one of the oldest and most widely practised welding techniques globally. Its simplicity and ruggedness make it a top choice for heavy-duty applications, especially in outdoor or harsh environments.
The welding equipment method used here consists of a consumable electrode coated in flux, which creates a gas shield and slag layer as it burns, protecting the molten weld from contamination.
SMAW is especially useful for welding thick materials like structural steel and is often used in shipbuilding, pipeline welding, and construction.
At Kirmell, we often utilise stick welding for structural steel projects, maintenance work, and on-site repairs where material conditions may not be ideal. This method allows our welders to work effectively even on rusty or painted surfaces, making it a reliable choice for fabricating heavy machinery frames and support beams.
Have a rugged job or on-site requirement? Get in touch with us and learn about durable solutions tailored to your industry.
How It Works:
An electric arc is formed between a flux-coated electrode (the “stick”) and the base material. The flux coating melts to create a protective gas shield and slag to cover the weld pool.
Common Uses:
- Building construction
- Shipbuilding
- Pipeline welding
- Heavy equipment repair
| Advantages | Limitations |
|---|---|
| Inexpensive and portable equipment | Generates slag that must be cleaned |
| Effective in windy and outdoor conditions | Less precise than MIG or TIG |
| Works on dirty or rusted materials | Not ideal for thin metals |
4. Flux-Cored Arc Welding (FCAW)
The Flux-Cored Arc Welding is a variation of MIG welding but is designed for tougher conditions and heavier materials. It was developed as an alternative to shielded metal arc welding and combines the benefits of both MIG and Stick welding. FCAW uses a tubular wire filled with flux instead of a solid wire, allowing it to be used with or without a shielding gas, depending on the application.
This process is particularly favoured in construction, shipbuilding, and heavy equipment manufacturing due to its high deposition rates and deep weld penetration. Its ability to operate effectively outdoors and in windy conditions makes it more versatile than traditional MIG, especially when building or repairing large metal structures.
How It Works:
The flux core inside the wire creates shielding gases and slag as it burns. It can be self-shielding (no gas needed) or dual-shielding (additional gas used).
Common Uses:
- Heavy steel construction
- Structural beams and bridges
- Shipbuilding
- Outdoor fabrication
| Advantages: | Limitations |
|---|---|
| High deposition rate | More spatter and slag than MIG |
| Effective for thick materials | Heavier equipment |
| Performs well outdoors | Not suitable for thin materials |
metal welding process
5. Laser Beam Welding (LBW)
Laser Beam Welding is a precise, high-energy fusion welding technique that uses a focused laser beam to melt and join metals. It is especially valuable in industries that demand fine detail, minimal heat distortion, and high automation potential. The process produces narrow, deep welds with a very small heat-affected zone (HAZ), making it ideal for applications requiring tight tolerances.
Originally developed for aerospace and defence, laser welding is now common in the automotive industry for joining body panels and in electronics for delicate assemblies.
To understand more about how laser technology is revolutionizing material processing, check out our guide on What is Laser Cutting in Manufacturing: A Beginner’s Guide.
How It Works:
The laser generates intense heat, melting the joint area. It can be automated and used in environments requiring tight tolerances and low distortion.
Common Uses:
- Automotive and aerospace sectors
- Electronic components
- Medical devices
- High-precision metal parts
| Advantages: | Limitations |
|---|---|
| High-speed, accurate welding | Very expensive |
| Minimal heat-affected zone | Requires a clean work surface |
| Clean finish and low distortion | Not suited for thick materials |
6. Ultrasonic Welding
Ultrasonic welding is a solid-state process that uses high-frequency mechanical vibrations under moderate pressure to join materials, typically plastics and thin metals. The friction generated at the interface causes localised melting or softening, forming a strong bond without requiring heat input from an external source.
This method is widely used in industries where cleanliness, speed, and precision are paramount. In electronics, ultrasonic welding is used for wiring and microcircuit assembly. In medical device manufacturing, it is used to assemble plastic components without contaminating the product.
How It Works:
The materials are held together under pressure while ultrasonic vibrations are applied, creating heat through friction at the joint interface.
Common Uses:
- Medical and electronic components
- Toy and packaging industries
- Wire harness assembly
- Small plastic parts
| Advantages | Limitations |
|---|---|
| No need for solder or adhesives | Not suitable for large or thick parts |
| Fast and clean process | Limited to thermoplastics and thin metals |
| Precise and controlled | Requires specialised equipment |
Conclusion
Welding is a foundational process in manufacturing, construction, and design. From the robust and rugged stick welding to the fine-tuned precision of TIG and laser welding, each type offers specific benefits based on the materials, project requirements, and working conditions.
Kirmell’s Welding & Manufacturing Services
As a trusted UK-based precision manufacturer, Kirmell provides high-quality welding and fabrication services to support a wide range of industrial needs. Our facility is equipped to handle both light and heavy-duty projects across sectors such as construction, infrastructure, and machinery.
Our Welding Capabilities Include:
- MIG and Stick welding for mild steel, stainless steel, and aluminium
- Custom fabrication of frames, enclosures, panels, and support structures
- CNC machining and laser cutting for tight-tolerance components
- ISO 9001:2015 certified processes to ensure quality and consistency
Kirmell offers not only technical expertise but also a strategic location in the UK, giving EU clients a cost-effective and low-tariff alternative to outsourcing in Asia or the U.S., especially relevant in today’s volatile trade environment.
Need a trusted welding and supply chain partner in the UK? Partner with Kirmell today to strengthen your operations.
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