Tag Archive for: welding

A factory worker welding metal components, surrounded by industrial equipment and bright sparks

MIG vs TIG Welding: Which is Best for Your Project?

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Welding is one of the most important processes in metal fabrication and construction. It joins two pieces of metal together by melting them and fusing them into one strong, solid piece. But not all welding is the same. Two of the most common and widely used types are MIG welding and TIG welding. Each has its own strengths, uses, and techniques.

If you’re unsure which one is best for your next project, don’t worry. In this guide, we’ll explain the differences between MIG and TIG welding in simple terms and help you choose the right method depending on your needs. We’ll also show how fabrication experts like Kirmell Ltd use both techniques to serve clients across various industries.

What is MIG Welding?

MIG welding stands for Metal Inert Gas welding, also known as Gas Metal Arc Welding (GMAW). In this method, a wire electrode is automatically fed through a welding gun. The gun also releases a shielding gas (like argon or a mix of gases) to protect the molten metal from contamination in the air.

The wire acts both as the electrode and the filler material. As it melts, it fills the gap between the two metal pieces, joining them together.

Key Features of MIG Welding:

  • Fast and efficient: MIG welding is known for its speed.
  • Easy to learn: Good for beginners or large-volume production.
  • Ideal for thin to medium-thickness metals.
  • Requires less cleanup than some other welding types.

A person wearing a welding helmet is focused on welding metal pieces together

What is TIG Welding?

TIG welding stands for Tungsten Inert Gas welding, also known as Gas Tungsten Arc Welding (GTAW). Instead of using a wire feed, TIG welding uses a non-consumable tungsten electrode to create the arc. A separate filler rod is manually fed into the weld area, while shielding gas (usually pure argon) protects the weld. Welding gas for a MIG welder is also sometimes an argon/carbon dioxide mix

TIG welding is a slower and more precise process. It gives the welder more control over the weld, making it ideal for detailed and delicate work.

Key Features of TIG Welding:

  • Highly precise and clean welds.
  • Best for thin materials and critical joints.
  • More difficult to learn, but produces high-quality results.
  • Can weld more types of metals, including stainless steel, aluminium, copper, and titanium.

Read in detail about other types of welding in our separate guide and understand the function of each.

A welder in a helmet is actively welding a pipe, surrounded by tools and equipment in a workshop environment.

What Are the Main Differences Between MIG and TIG Welding?

Let’s compare them side by side to help you see the differences clearly:

 

Feature  MIG Welding TIG Welding
Ease of Use Easier to learn, semi-automated Harder to master, manual control is needed
Speed Faster and more efficient Slower, better for detailed work
Precision Good for general jobs Excellent for fine and aesthetic welds
Metal Thickness Best for thicker or medium sheets Best for thin metals
Appearance Slightly more spatter, requires cleanup Clean, smooth, and visually neat
Welding Position Works well in all positions Best suited for controlled environments
Filler Material Wire-fed automatically Manually added filler rod
Shielding Gas MIG welding gas is Usually argon or CO2 mix Typically pure argon

Read in detail about the technical differences between MIG and TIG welding.

When Should You Use MIG Welding?

MIG welding is an excellent choice for:

  • High-volume production: Because it’s fast, it’s ideal for large quantities.
  • Thicker metals: It handles heavy materials like mild steel and stainless steel very well.
  • Structural work: Frames, brackets, automotive parts, and general fabrication.
  • Outdoor welding (with proper shielding gases and equipment).

It’s also preferred when appearance is not the top concern, but speed and strength are.

At Kirmell, we often use MIG welding for projects that require reliable joints at scale, especially in the production of brackets, supports, and medium-duty industrial components. Contact us now for your welding projects, and let our experienced staff help you with the most efficient and high-quality welding solution for your needs.  

When Should You Use TIG Welding?

TIG welding is the better option when:

  • You need a neat and clean finish.
  • The metal is very thin, like sheet aluminium or stainless steel.
  • The weld must be highly precise, such as in aerospace, medical equipment, or food-grade applications.
  • You’re welding speciality metals that require careful control.

TIG is especially valuable for projects where appearance matters just as much as strength. At Kirmell, we use TIG welding for precision-critical applications where clean, accurate, and high-quality welds are essential, such as in stainless steel enclosures, bespoke components, and specialist assemblies.

A close-up of a TIG welding process in an industrial environment, showcasing bright sparks and a welder's focused expression.

What To Consider When Choosing Between MIG and TIG?

Choosing the right welding method isn’t just about picking one that “looks” better it depends on the specific needs of your project. Here are the key factors you should carefully consider before deciding whether to go with MIG or TIG welding:

  • Type of Metal Being Welded

Different metals behave differently when welded. MIG welding is excellent for mild steel, stainless steel, and other commonly used metals. It works well in industrial settings where fast welding is needed on thicker, tougher materials.

On the other hand, TIG welding is more suitable for non-ferrous metals such as aluminium, magnesium, copper, and titanium. These metals are more sensitive and require a more controlled welding method. TIG offers control and is especially useful when working with materials that need clean, high-quality finishes or are part of precision products.

  • Thickness of the Material

Material thickness plays a major role in deciding the welding method. MIG welding is ideal for medium to thick materials, as it can quickly deposit filler metal and create strong welds that penetrate deeply.

TIG welding, by contrast, excels at thin-gauge materials where heat control is crucial. If you use MIG on very thin sheets, it might cause burn-through or warping. So, if you’re welding thin stainless steel panels, delicate tubing, or aluminium sheets, TIG gives you the finesse needed to avoid damaging the material.

  • Required Weld Appearance and Cleanliness

Not all welds are hidden. If your project involves visible joints, like in decorative furniture, exposed piping, or artistic structures, the appearance of the weld becomes important.

TIG welding is known for producing clean, smooth, and visually appealing welds, often without needing extra grinding or finishing. This makes it ideal for jobs where aesthetics matter, like food processing equipment, kitchen installations, or display pieces.

MIG welds, while strong and efficient, can be messier and may require post-weld cleaning to remove spatter and improve the look.

  • Speed and Efficiency of the Process

If your project is large and requires many welds in a short time, a MIG welding welder is a better choice. It’s much faster than TIG, mainly because it uses a continuous wire feed that allows you to weld for longer periods without stopping to replace electrodes or manually feed filler rods.

TIG welding, while slower, offers better precision and control. It’s a great fit for high-quality work but may not be the most time-efficient method for bulk jobs or tight production deadlines.

  • Skill Level and Labour Costs

Your team’s experience and available skillset are also important. MIG welding is often recommended for beginners or for teams that need to train operators quickly. The process is semi-automated, making it easier to produce consistent results even with less experience.

TIG welding, on the other hand, is more technically demanding. The TIG welding process requires steady hands, careful coordination between the torch and filler rod, and a solid understanding of weld pool control. This means more time spent on training or higher labour costs if hiring skilled TIG welders.

  • Environment and Working Conditions

Welding conditions can affect the choice, too. MIG welding is generally better suited for outdoor or less controlled environments (though wind shielding is still required). In contrast, TIG welding is best performed indoors or in stable environments, where there’s full control over factors like humidity, airflow, and cleanliness.

If your welding has to be done on a job site with unpredictable weather or limited equipment setup, MIG is more practical because MIG welding equipment is smaller compared to TIG. 

A man using a welding torch to weld metal in a factory setting. Sparks fly as he focuses on his work.

Industries That Use MIG and TIG Welding

Both welding methods are used across many industries, often depending on the project’s needs:

  • Automotive: MIG for structural components, TIG for fuel tanks and exhaust systems.
  • Aerospace: TIG welding is widely used due to the need for high precision.
  • Construction: MIG welding is preferred for fast, durable joints in structural frameworks.
  • Medical and Food Equipment: TIG welding is ideal for clean, contamination-free welds.
    Art and Architecture: TIG welding allows for visually attractive joints in sculpture and design.

A Look Inside Kirmell’s Welding Capabilities

At Kirmell Ltd, welding is one of the core services we provide. With decades of experience and a fully equipped facility, we use both MIG and TIG welding to handle a wide range of fabrication projects from simple metal brackets to complex assemblies.

Whether it’s speed, accuracy, or a smooth finish you need, we’ll select the right method to match your goals. Our team works with mild steel, stainless steel, aluminium, and more, always delivering high-quality, long-lasting welds.

Conclusion

So, which is better, MIG or TIG? The answer really depends on your project.

If your priority is speed, volume, and affordability, MIG is a smart choice. It’s efficient, beginner-friendly, and perfect for general manufacturing tasks.

If you need precision, a polished look, or you’re working with thinner or speciality metals, then TIG will give you the superior result you’re after, even if it takes more time and effort.

Still unsure? A professional fabrication team can help you decide which method suits your goals.

Need Expert Welding Support? Trust Kirmell Ltd

At Kirmell Ltd, we offer professional MIG and TIG welding services as part of our wider fabrication solutions. Whether you’re creating prototypes, small custom parts, or high-volume production runs, our team is ready to assist.

With the right tools, experienced welders, and quality assurance at every step, we ensure that your components are built to last and match your exact specifications.

Ready to start your welding project? Contact us today at sales@kirmell.co.uk or visit the contact us page and fill out the form with your details, and our expert will reach out to you.

FAQs

 

What is the difference between MIG and TIG welding?

MIG welding uses a wire that feeds automatically and is great for fast, strong welds on thick materials. TIG welding uses a non-consumable tungsten electrode and a separate filler rod, making it better for thin materials and detailed, clean welds.

 

Which welding method is easier to learn?

MIG welding is easier to learn because the wire feeds automatically, and the process is more forgiving for beginners. A TIG welding machine takes more time to master as it requires precise hand control and coordination.

 

Can both MIG and TIG welding be used on aluminium?

Yes, both methods can weld aluminium, but TIG welding is usually preferred for aluminium because it gives better control and a cleaner finish.

 

Which is better for outdoor welding, MIG or TIG?

MIG welding is more suitable for outdoor use, especially with the right shielding gas setup however keep in mind that it is sensitive to wind. TIG welding is best done indoors in a clean, controlled environment to avoid contamination.

 

Does Kirmell offer both MIG and TIG welding services?

Yes! Kirmell Ltd provides professional MIG and TIG welding services for projects of all sizes, from industrial brackets and frameworks to precise, high-quality components requiring detailed TIG welds

 

A metalworker grinds metal, producing a shower of sparks in the process

What is Metal Fabrication? A Beginner’s Guide

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Metal is a part of almost everything around us. Whether it’s the car you drive, the spoon you eat with, the building you live in, or the machines in factories, metal plays an important role. But metal doesn’t naturally come in the shapes we use. It has to go through a process to become useful, and that process is called metal fabrication. In this guide, we’ll explore what metal fabrication really means, how it works, and why it’s such a big deal in the world of manufacturing and construction.

Understanding Metal Fabrication in Simple Words

Metal fabrication is the process of turning raw metal materials into finished parts or products. This involves different steps like cutting, bending, joining, and shaping metal into the desired form. Think of it like baking a cake. You start with ingredients like flour, eggs, and sugar, and through mixing and baking, you turn them into a cake. In the same way, metal starts as sheets or rods, and through different processes, it becomes things like pipes, machine parts, railings, or even car frames.

This work is usually done in workshops or factories known as fabrication shops or metal fabrication facilities. Skilled workers, fabricators or metalworkers use machines and tools to cut and shape metal. Some of these processes are manual, but many use machines or computers for more precision.

At Kirmell Ltd, we offer a full range of fabrication services, including CNC machining, laser cutting, presswork, and welding. Our team works with clients across the UK and EU to deliver high-quality metal parts that meet industrial standards and tight production deadlines. Contact us now and get in touch with our expert if you are looking for industrial manufacturing services.   

welding process

Why is Metal Fabrication So Important?

Without metal fabrication, we would not be able to build many of the things that are essential to our daily lives. From simple tools like wrenches and kitchen knives to large structures like buildings, aeroplanes, and bridges, metal fabrication is what makes it all possible. It allows engineers and designers to bring their ideas to life by shaping metal in ways that suit different purposes.

Metal is strong and durable and can handle heat, pressure, and heavy loads. That’s why it’s used in many industries, including automotive, aerospace, construction, energy, agriculture, and even medicine. Imagine building a skyscraper or a ship without fabricated metal parts; it simply wouldn’t work. Metal fabrication gives us the power to build strong, long-lasting, and efficient products.

How the Metal Fabrication Process Works

Here is a detailed overview of the process of how metal fabrication works:

  • Design and Planning

Everything starts with a plan. Engineers or designers create technical drawings or digital blueprints of the product. These blueprints include the size, dimensions, shape, and materials required. Today, most of this is done using computer software like CAD (Computer-Aided Design) to ensure high precision.

  • Material Selection

Once the design is ready, the next step for sheet metal fabrication is choosing the right metal. The choice depends on the product’s purpose. For example, stainless steel is used for kitchen items, aluminium is used for lightweight parts like aeroplane components, and carbon steel is used for construction structures. 

  • Cutting the Metal

The raw metal comes in sheets, tubes, or bars, and it needs to be cut down to size. Cutting is done using tools like:

  • Laser cutters (for clean and precise cuts)
  • Plasma cutters (for thick metal sheets)
  • Shears or saws (for simpler cuts)
  • Waterjet cutters (when no heat should be applied)

Each method is chosen based on the type and thickness of the metal and the level of detail needed.

A worker preparing metal for welding in a factory

  • Forming and Shaping

After cutting, the metal is bent or shaped into the required form. Machines like press brakes apply pressure to fold or curve the metal. Rolling machines are used for cylinders or rounded items. Forming gives the metal its basic structure.

  • Welding and Assembling

The cut and shaped pieces are now joined together. The most common way is welding, which melts the edges of the metal and fuses them. Other joining methods include:

  • Riveting
  • Screwing or bolting
    Using adhesives (in lighter applications)

This step is where the product begins to take its final shape.

  • Finishing and Surface Treatment

The last step is making the product look good and perform better. Finishing can include:

  • Grinding to smooth the surface
  • Sandblasting to clean off any debris
  • Painting, powder coating, or polishing for appearance and rust protection

Sometimes, special coatings are added to make the product heat-resistant or water-repellent.

Real-Life Uses of Metal Fabrication

To better understand how common metal fabrication is, let’s look at some real-world examples. In the construction industry, metal fabrication is used to make steel beams, metal railings, doors, and windows. In the transportation industry, cars, buses, aeroplanes, and trains are full of metal parts made through fabrication, from the frame and engine parts to small components like brackets and panels.

In the world of appliances, items like refrigerators, ovens, and washing machines all use fabricated metal. Even medical tools, surgical scissors, hospital beds, and machines like X-rays have fabricated metal parts.

If you look around your home, you’ll probably find many items made through metal fabrication, like your kitchen sink, metal shelves, bed frames, or even decorative items like lampstands. It’s truly everywhere.

Saw cutting of a metal

Benefits of Metal Fabrication

Metal fabrication offers countless benefits, like:

  • High Strength and Durability

Metal parts made through fabrication are strong enough to handle extreme stress, heavy loads, and rough conditions. This is why metal is used in bridges, skyscrapers, vehicles, and tools that must last a long time.

  • Design Flexibility and Customisation

One of the best things about metallic fabrications is that they allow for custom designs. Need a one-of-a-kind machine part? No problem. With modern tools and machines, metal can be shaped into almost any form, making it easy to meet unique project needs.

  • Efficiency and Speed

Thanks to automation, CNC machines, and advanced cutting tools, metal parts can be fabricated quickly without compromising quality. This is especially useful when making large batches or meeting tight project deadlines.

  • Cost Effective for Large-Scale Production

While initial setup (like buying machines) might be costly, metal fabrication becomes very economical when producing items in bulk. Once the machines are programmed, they can create hundreds or thousands of identical parts quickly and accurately.

  • Recyclability and Sustainability

Most metals used in fabrication, such as steel, aluminium, and copper, can be recycled. This reduces waste, saves resources, and supports environmentally friendly manufacturing.

Its versatility makes it one of the most valuable processes in the modern industrial world. At Kirmell Ltd, we offer all key stages of the metal fabrication process, from precision presswork and component cutting to custom laser finishing, making us a trusted fabrication partner for the UK and EU industries. Read our brochure to learn more about our services and how we can help you. 

metal cutting using saw machine

Conclusion 

Metal fabrication may sound like a complex topic, but at its core, it’s simply about taking raw metal and turning it into something useful. Through cutting, bending, welding, and shaping, metal is transformed into products that help us live our modern lives, from cars and buildings to tools and appliances.

Understanding metal fabrication is important not just for engineers or manufacturers but for anyone curious about how the world around them is built. It’s a process that combines creativity, skill, and technology, and it’s all around us every day.

Looking for a Reliable Metal Fabrication Partner? Trust Kirmell Ltd

If you’re searching for a dependable metal fabrication partner to support your business, Kirmell Ltd is here to help. With decades of experience and a commitment to quality, we serve industries across the UK and EU with precision-engineered components and tailored fabrication services.

Whether you’re looking for a reliable supplier for batch components or help with a one-off development project, we have the expertise, equipment, and flexibility to support you.

Here’s what we offer:

  • Presswork: From medium to heavy-duty and deep-drawn pressings, we produce a wide variety of stamped parts using both traditional and CNC-assisted equipment.
  • Fabrication & Assembly: Our team handles welded assemblies and fabricated parts with rapid response capabilities and short-run flexibility.
  • Laser Cutting & CNC Machining: High-precision, cost-effective solutions for small or large volumes, suitable for industrial and engineering applications.
  • Component Development: We work with clients during early design stages and provide prototyping, material selection guidance, and tooling support.
  • Custom Products: We produce a wide range of items like pallet feet, nesting plugs, cubicle hardware, ladder standoffs, and more, all manufactured to ISO 9001:2015 and ISO EN1090 standards.

From rapid turnaround and flexible production to long-term supply partnerships, Kirmell is here to simplify your fabrication process and deliver components you can trust.

Ready to get started?

Visit our Contact Page and fill out the form provided to get in touch with our experts. 

FAQs 

 

What does a metal fabricator do?

A metal fabricator is someone who cuts, shapes, and joins metal to make useful parts or products. They use tools and machines to turn raw metal into things like frames, brackets, or gates. Metal fabricators follow drawings or designs to make sure each piece is the right size and shape.

 

What are examples of metal fabrication?

Metal fabrication is used to make many everyday items. Examples include car parts, metal doors, fences, kitchen sinks, shelves, and parts of machines. It also includes things like steel beams for buildings and pipes for plumbing. If it’s made from metal and has a shape, it likely came from metal fabrication.

 

Is metal fabrication done by hand or by machines?

Both! Some small or detailed work is done by hand using simple tools, but most modern metal fabrication is done with machines like laser cutters, press brakes, and welding machines. These machines help make parts faster and more accurately.

 

What materials are used in metal fabrication?

Common materials include steel, stainless steel, aluminium, copper, and brass. The choice depends on what the product will be used for. For example, stainless steel is great for kitchens because it doesn’t rust, while aluminium is light and good for cars or aircraft.

 

Can I get custom metal parts made?

Yes! at, Kirmell, we make custom parts based on your design or idea. Whether you need one special item or hundreds of the same part, custom fabrication can be done to fit your exact needs.

 

A factory worker performing welding duties

Different Types of Welding and How They’re Used

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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.

A worker welding two metal joint

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 operateLess suitable for outdoor use (wind affects shielding gas)
High welding speed and productivityNot ideal for thick materials
Produces clean welds with minimal slagRequires 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

Welding process in a factory

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
AdvantagesLimitations
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
AdvantagesLimitations
No need for solder or adhesives
Not suitable for large or thick parts
Fast and clean processLimited 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.

FAQs 

 

Which welding method is best for beginners?

MIG welding is generally considered the best option for beginners. It’s easy to learn, produces clean welds, and is ideal for light to medium metal fabrication like auto repairs, furniture, and DIY projects.

 

What is the safest welding process?

While all welding processes can be safe when proper precautions are taken, MIG welding is often considered one of the safest due to its ease of control and minimal open arc exposure. However, personal protective equipment (PPE) and good ventilation are essential for any welding type.

 

How hot is a welding arc?

A welding arc can reach temperatures between 6,000°C to 10,000°C (10,800°F to 18,000°F) depending on the method. This intense heat is what allows metals to melt and fuse together, so safety measures like arc shields and fire-resistant clothing are a must.

 

What types of welding services does Kirmell offer?

Kirmell offers MIG, TIG, and Stick welding as part of its full-service metal fabrication capabilities. These are suitable for steel, aluminium, and stainless steel projects ranging from structural frameworks to custom components.

 

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Eyre Street
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