What are the Different Types of Welding?

Since ancient Egypt, humans have welded base metal in one way, shape or form. Welding does not get the credit it deserves, but few skills human beings have created have had as much of an impact on the average person’s daily life.

Here are the major welding techniques, how they were or are used. Keep reading to learn how you can determine the types of welding processes you need for any projects you are working on.

And for a quote on welding services, contact Glenn Metalcraft today.

Welding’s Impact

Just about everywhere you look, various forms of welding affect our lives. Your vehicle, furniture, appliances, even some electronics have some form of welding (which is different from soldering.) From the early days of forge welding through today’s most computer-driven, semi-automatic, and sophisticated welding methods, welding has helped us bond metal to create things that truly enhance our lives.

Forge Welding

Forge welding was the earliest form of welding. It started with ancient Egypt and spawned blacksmithing. It involves heating two metals to the point of a molten status and then pounding them into a single metal object.

Braze Welding

This type of welding goes far back as well. Braze welding has been found in archeological sites worldwide. It was used for bonding bronze, silver, gold, and steel. This type of welding is still used today, primarily when working with softer metals that melt under lower temperatures.

Arc Welding

Arc welding is the most common form of welding and was developed in England and France in the early 1800s. It uses an electrical pulse to melt metal at extremely high temperatures and carry it across a joint via an arc to fill the arc with an incredibly strong bond.

Arc welding came into prominence during World War I and eventually became a primary bonding method in modern manufacturing. In the war (and subsequent wars,) it was a vital tool in repairing ships quickly so they could return to battle or be retrofitted with new equipment.

Arc welding has improved in equipment, safety, cost, and weld quality and is now used in several different forms for various purposes. A few of the more common methods of welding are outlined below.

Metal Inert Gas (MIG) Gas Metal Arc Welding (GMAW)

MIG welding is exceptionally simple but produces high-quality welds, and because of that, it is a favorite for many new welders. The welding process occurs by feeding wand-based filler metal into the portion of the weld that is arced, while gas expels to shield it from external elements.

It is not generally used to weld metals outside because of the need for a gas shield. It can be used, though, for many different types of thickness, making it a “go-to” for simple type welds. The wire serves as the electrode and melts when the arc travels from the tip of the wire to the base metal. This action creates a pool that hardens into a weld.

The arc process is controlled by the welder, which allows them to proceed at their own pace. When completed, a MIG weld is smooth, tight, and very linear.

Stick Welding Shielded Metal Arc Welding (SMAW)

Stick welding is the most used type of welding for non-complex projects because it is easy to learn, inexpensive, and easy to perfect. The downside to stick welding is that it splatters a lot, depending on the welder’s skill. The splatter makes cleanup afterwards nearly inevitable.

An arc from the stick to the base metal is created, and the stick serves as the filler metal. The arc will generate heat and flux, coat the stick, vaporize, and protect the metal from oxidation. It can be used outdoors and in adverse weather, including rain, ice, snow, and wind. Additionally, stick welding works on rusted, dirty, and painted surfaces.

Another upside to this welding method is that there are many electrode types, and they are easy to swap. This flexibility makes stick welding very versatile and able to work with most metals, including stainless steel. Because the process will create heat, it is not the ideal welding method for thin metals.

TIG – Gas Tungsten Arc Welding (GTAW)

This type of welding uses a tungsten electrode and requires no filler metal, meaning that you can join the two metals directly. Shielding gas is needed for this type of welding, and it protects the weld from external elements. There is no splatter, and the bond is incredibly precise.

Flux Cored Arc Welding (FCAW)

FCAW uses a wire as the electrode, which has a core of flux that creates a gas shield around the weld. FCAW is best with thicker, heavier metals, making it a favorite for repairing heavy equipment and components with large metal seams, like barges. The FCAW process is clean, does not need external gas, and is affordable.

Plasma Arc Welding

A smaller arc helps create a very precision-oriented weld with Plasma Arc Welding. This method also uses a different type of torch, which runs much hotter than a traditional torch. The torch is so hot that even base metals can melt, allowing plasma welding with no filler metal.

Plasma Arc welding creates deep weld penetration on relatively narrow weld channels. Plasma Arc Welding produces attractive welds that are exceptionally strong. It can also be accomplished at very high speeds, making it ideal for some forms of manufacturing.

Other Types of Welding

While the welding methods outlined above are the most popular, several other types of welding are also frequently used. Each of these methods are used in hybrid situations, usually in some form of manufacturing. A few include:

Laser Beam Welding
Electron Beam Welding
Electroslag
Atomic Hydrogen Welding

What are the Different Types of Welding: Final Thoughts

Generally, the two most popular types of welding, stick, and MIG (GMAW), are used because they are easy, require little specialized equipment, are inexpensive, and the weld produced is superior and great looking. They are the most popular because anyone from beginner to expert can do them with little training time.

For more information on welding, contact Glenn Metalcraft.

Automated welding offers several advantages to businesses, including reduced costs and higher return on investment. This article discusses the many benefits of robotic welding and how it can help your business.

What are the Benefits of Robotic Welding?

1. Increased Productivity

Compared to manual welding, robotic welding systems can achieve faster results.

It can improve productivity as the robotic systems get the job done quickly. You don’t have to wait hours when you have robots working—the cycle time is lesser, which means you can get more things done.

Whether you have acquired new or used robots, the output is still the same as long as the purchased robotic welding systems are functional and in good working order or when you hire the right company to help you with fulfillment. Most importantly, robot arms don’t get tired. There’s no need for breaks.

You can have welding robots work as many hours as possible if you have several projects that need to get done. No one has to take vacations or sick leaves. If you’re flexible or have some people who can supervise, your robotic welding systems can work 24/7.

2. Reduced Mistakes

With manual welding, it’s possible to make mistakes.

Robotic systems, on the other hand, are designed to work effectively and efficiently. So long as the machines are well maintained and in good working condition, they make fewer to no mistakes.

The weld quality will be exceptional with industrial robots. You don’t have to worry about manual welders’ common mistakes, such as choosing the wrong wires or the size gun or using the incorrect voltage. These mistakes are reduced significantly, which in return benefits your company.

3. Consistency

Welding processes are used in several industries such as construction and automotive.

Before the process can begin, a welding method is chosen. The base metals and equipment are prepped, measured, and positioned. Also, the welder has to be certified, prepared, and trained. They need to adhere to the standard procedures to ensure consistency and also avoid contamination.

When the worker fails to do proper shielding, the result could be weak or porous. You can significantly reduce or completely avoid the problems associated with manual welding when you automate the process.

With robotic arms helping, you know that the output is always consistent. You won’t have to worry about other issues or contamination. Robotic automation ensures high-quality output and consistency all of the time.

4. Safety and Cost Savings

When it comes to welding, safety is the topmost priority.

Welding injuries can occur when the workers don’t take the proper precautions, such as wearing safety glasses, safety boots, welding helmets, and hearing protection. When the welder isn’t careful, they could lose their hearing or eyesight and suffer general burns.

It’s essential to keep all the laborers safe, or the company may pay for the medical bills or other damages if the laborer isn’t insured. You can avoid all these when with the robotic welding process. Robot arms don’t get hurt, and you won’t have to pay for insurance when you have people working for you. Over time, it can add to massive savings on your part.

Keep in mind that running a business means reducing all the expenses wherever possible to maximize your profit. A higher return of investment is entirely possible with automated welding.

The cost to acquire robots may be higher, but it’s cost-effective in the long run. So long as you know how to maintain your robots properly, they should work efficiently for many years, helping you generate more revenue for your business.

5. Robots Can Start Immediately

Whether you’re a startup or an established business, it’s essential to have a good hiring process in place to ensure that you have the right people in your team.

Welding requires the right skill and concentration — you can’t hire anyone for this. They need to have the training and experience for them to work efficiently and effectively. Also, you will, of course, need to pay for labor.

You can save time when you have robots working for you. There’s no need to spend weeks or months looking for more people to help you finish projects if you’re an established company.

No more labor costs too, which is one of the benefits of robotic welding. Most importantly, you don’t have to wait for them to get started. Robots can begin working on your project at any time—no need for training or hiring process. Robots are already designed to do their job the best way possible.

6. High-Quality Output

When the workers are not highly trained or experienced, they may make mistakes or even injure themselves. Major defects can include hot and cold cracking, blowholes, penetration defects, or iron contamination.

Before starting the process, welders need to do some preparation, take extra precautions, store and handle metal the right way, choose the right gun and electrodes, etc. If they fail, the output may not be that exceptional.

With automated welding, the output will be of top-notch quality if you have the best robots in the market. In return, you get repeat clients.

Invest in Robotic Welding

Because of increased productivity and improved quality, you can complete more projects in less time. In return, your business can generate more revenue.

If you want to drive more revenue, we suggest investing in robotic welding. And that’s where Glenn Metalcraft comes in.

We can provide both manual and robotic welding services to our clients. Our team can handle small to large volumes of projects. We have been helping businesses for several years and still counting.

One of our top priorities is to provide the best welding solutions to businesses. Get in touch with us today to request an estimate for your next robotic welding project.

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