What Are All the Different Types of Welding? 9 Welding Processes and Their Applications

If you’re like most people, you probably assume welding is welding. A substance is melted, then used to join two metals, and voilà — welding. 

But the fact is, there are many different welding processes, each valued for its unique application.

Whether you're curious which process best meets your needs or just want to learn more about welding, you’ll want to keep reading. Here, the team at Madden Fabrications provides a detailed look at eight welding processes, their most common applications, and where you can find professional metal fabrication in Portland, Oregon.

Table of Contents

• What Are the 4 Main Types of Welding?

• What Are the Different Types of Welding​? 9 Common Processes 

• Madden Fabrication: Professional Commercial, Residential, & Industrial Metal Fabrication in Portland, Oregon

What Are the 4 Main Types of Welding?

There are a variety of different types of welding, and the one you choose depends on the application. The four main types of welding include: 

1. Stick 

2. MIG gas metal arc 

3. TIG oxy-acetylene 

4. Gas tungsten arc welding

What Are the Different Types of Welding​? 9 Common Processes

#1: Stick or Shielded Metal Arc Welding

The manual process of stick welding, also known as shielded metal arc welding (SMAW), makes use of a consumable electrode (stick) coated in flux to create an arc and join one or more metals. 

During the welding process, the flux coating melts and produces a shielding gas that protects the welding area from atmospheric contamination. 

Stick welding is known for its portability, ability to weld a large range of metals, and reliability in harsh conditions. Major uses include maintenance, shipbuilding, construction, manufacturing, and repairs.

 #2: MIG (Gas Metal Arc Welding)

MIG (metal inert gas) welding is also commonly referred to as gas metal arc welding (GMAW). This process combines a continuously fed wire electrode and a shielding gas to join two metals. 

During the process, an electrical arc is created between the workpiece and the wire, which causes the metal to melt and allows the metals to fuse. A shielding gas is used throughout the process to protect the weld area from atmospheric contamination.

MIG welding is popular because it’s easy to learn and quick to use. It is suited to sheet metal welding, home improvement projects, automotive repairs, the fabrication of industrial equipment, pipelines, and heavy construction like bridges.

#3: TIG (Gas Tungsten Arc Welding)

TIG, or gas tungsten arc welding (GTAW), forms a weld by using a non-consumable tungsten electrode to create an arc that melts the base metal and any filler metal. An inert gas (usually helium or argon) shields the area surrounding the weld from atmospheric contamination. 

TIG welding produces a precise, high-quality weld that is useful in a variety of industries, such as automotive, aerospace, and electronics.

If you’re in need of commercial, residential, or industrial metal fabrication in the Portland area, Madden Fabrication would love to serve you. Reach out today to discuss your project.

#4: Oxy-Acetylene Welding

Oxy-acetylene welding, or oxyfuel welding, burns acetylene and oxygen to create a high-heat flame to melt and fuse metal, often with the addition of a filler rod. This type of welding is especially good for welding thin metal sections and tasks involving heating. 

While many industrial settings have replaced it with newer welding technologies, oxy-acetylene remains a valuable option for emergency repairs, other repair work, art, and fabrication.

#5: Flux-Cored Arc Welding

A semi-automatic or automatic arc welding process, flux-cored arc welding (FCAW) uses a continuously fed tubular electrode filled with flux. The process may be done with or without external shielding gas. 

The flux stabilizes the arc, deoxidizes the weld, and protects the weld from atmospheric contamination.

This type of welding can be better used outdoors than some other welding processes since there’s not as much concern about the shielding gas, especially with self-shielded wires.

Flux-cored arc welding is used in heavy construction, shipbuilding, pipeline welding, repair work, hardfacing, and welding thicker materials where deep penetration is required.

#6: Thermit Welding

Thermit welding is also referred to as thermite or exothermic welding. This process uses a chemical reaction to generate intense heat that fuses metal parts together by igniting a mixture of metal oxide and aluminum powder, producing molten iron and aluminum oxide.The created molten iron is used to fill a mold and join the metal pieces.

This form of welding is used in joining heavy metal components, railroad track repair, and other scenarios that require a strong, reliable weld.

#7: Submerged Arc Welding

In submerged arc welding (SAW), a continuous, solid or tubular electrode is fed into a molten weld pool that is submerged under a blanket of granular flux. The flux shields the arc and molten metal from the atmosphere, producing consistent, high-quality welds and minimal spatter. 

This form of welding is especially effective for welding flat, thick, or horizontal metal sections. It’s commonly used in industries like railroading, construction of wind turbines, heavy fabrication, and shipbuilding.

#8: Electron Beam Welding

A fusion welding process, electron beam welding (EBW) uses a focused beam of high-velocity electrons to join metals. The process is executed within a vacuum to keep the electrons from scattering and to minimize oxidation of the materials being welded. 

This welding method is renowned for creating narrow, deep welds with high joint strength and minimal heat-affected zones.

Electron beam welding is mainly utilized in industries that require minimal distortion in welds, high precision, and strength, such as medical device manufacturing, aerospace, and nuclear.

#9: Forge Welding

Forge welding is an ancient metalworking technique that involves heating two pieces of metal to a high temperature and then joining them by hammering or pressing them together. Forging is a solid-state welding process, meaning the metals don't melt during the process. 

This process is used in blacksmithing and other scenarios where creating strong, durable bonds is required.

Madden Fabrication: Professional Commercial, Residential, & Industrial Metal Fabrication in Portland, Oregon

Not sure what type of welding is required for your job? Leave it to the experts at Madden Fabrication. 

Located in Portland, Oregon, we’re a metal fabrication facility serving the industrial, commercial, and residential construction industries. Our team provides 24/7 service to meet your scheduled maintenance or emergency repair needs to keep your business up and running — while helping prevent costly downtime. 

The mission of our team is to develop long-lasting relationships with our clients through superior service and dedication to our craft. Contact us today to learn more about the types of welding we offer and how we can meet your unique needs.