Arc welding is a process of joining metals by using an electric arc that melts the base metal and a filler material. Arc welding is one of the most widely used welding methods because of its versatility, efficiency, and low cost. There are many types of arc welding, each with its own advantages and disadvantages. In this article, we will introduce 11 types of arc welding and their applications and benefits.
1. Shielded Metal Arc Welding (SMAW)
Shielded metal arc welding (SMAW), also known as stick welding or manual metal arc welding (MMAW), is the most common and simplest type of arc welding. It uses a consumable electrode coated with a flux that creates a protective gas shield around the arc and the weld pool. SMAW can be used for welding various metals and alloys, such as carbon steel, stainless steel, cast iron, and nickel. SMAW is suitable for outdoor welding, repair work, and fabrication of structures and pipelines.
Some of the benefits of SMAW are:
It is easy to learn and operate.
It does not require a shielding gas or a wire feeder.
It can weld in any position and direction.
It can weld thick and thin materials.
It can weld in windy or rainy conditions.
Some of the drawbacks of SMAW are:
It produces slag that needs to be removed after welding.
It has a low deposition rate and efficiency.
It has high spatter and smoke emissions.
It requires frequent electrode changing.
2. Gas Metal Arc Welding (GMAW)
Gas metal arc welding (GMAW), also known as metal inert gas (MIG) welding or metal active gas (MAG) welding, is a type of arc welding that uses a continuous wire electrode fed through a torch and a shielding gas that protects the arc and the weld pool from atmospheric contamination. GMAW can be used for welding various metals and alloys, such as carbon steel, stainless steel, aluminum, copper, and magnesium. GMAW is suitable for high-speed production, automation, and robotic welding.
Some of the benefits of GMAW are:
It has a high deposition rate and efficiency.
It produces smooth and clean welds with minimal spatter and slag.
It can weld thin and thick materials.
It can weld in all positions.
Some of the drawbacks of GMAW are:
It requires a shielding gas and a wire feeder.
It is sensitive to wind and drafts.
It may cause porosity if the shielding gas is contaminated or insufficient.
It may cause burn-through if the wire feed speed is too high or the voltage is too low.
Read GMAW vs. CO2 Welding: A Comparison of Two Metal Arc Welding Processes.
3. Flux Cored Arc Welding (FCAW)
Flux-cored arc welding (FCAW) is a type of arc welding that uses a tubular wire electrode filled with a flux that generates a shielding gas around the arc and the weld pool. FCAW can be used for welding various metals and alloys, such as carbon steel, stainless steel, nickel, and hard facing. FCAW is suitable for outdoor welding, heavy-duty fabrication, shipbuilding, and offshore construction.
Some of the benefits of FCAW are:
It has a high deposition rate and penetration.
It can weld in all positions and directions.
It can weld in windy or rainy conditions.
It can weld dirty or rusty materials.
Some of the drawbacks of FCAW are:
It produces slag that needs to be removed after welding.
It has high spatter and smoke emissions.
It may cause porosity if the flux is contaminated or moist.
It may cause cracking if the weld metal is too hard or brittle.
4. Gas Tungsten Arc Welding (GTAW)
Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding or heliarc welding, is a type of arc welding that uses a non-consumable tungsten electrode and a shielding gas that protects the arc and the weld pool from atmospheric contamination. GTAW can be used for welding various metals and alloys, such as carbon steel, stainless steel, aluminum, titanium, copper, and nickel. GTAW is suitable for high-quality welding, precision work, thin materials, and complex shapes.
Some of the benefits of GTAW are:
It produces smooth and clean welds with no spatter or slag.
It can weld thin materials without distortion or burn-through.
It can weld dissimilar metals or alloys.
It can produce aesthetic welds with fine beads.
Some of the drawbacks of GTAW are:
It has a low deposition rate and efficiency.
It requires high skill and concentration.
It requires a shielding gas and a filler material (optional).
It is sensitive to wind and drafts.
5. Plasma Arc Welding (PAW)
Plasma arc welding (PAW) is a type of arc welding that uses a constricted arc that is forced through a small nozzle and a shielding gas that protects the arc and the weld pool from atmospheric contamination. PAW can be used for welding various metals and alloys, such as carbon steel, stainless steel, aluminum, titanium, copper, and nickel. PAW is suitable for high-quality welding, precision work, thin materials, and narrow gaps.
Some of the benefits of PAW are:
It has high energy density and penetration.
It produces smooth and clean welds with no spatter or slag.
It can weld thin materials without distortion or burn-through.
It can weld dissimilar metals or alloys.
Some of the drawbacks of PAW are:
It has a low deposition rate and efficiency.
It requires high skill and equipment costs.
It requires a shielding gas and a filler material (optional).
It is sensitive to wind and drafts.
6. Submerged Arc Welding (SAW)
Submerged arc welding (SAW) is a type of arc welding that uses a consumable wire electrode and a granular flux that covers the arc and the weld pool from atmospheric contamination. SAW can be used for welding various metals and alloys, such as carbon steel, stainless steel, nickel, and hard-facing. SAW is suitable for high-speed production, automation, and thick materials.
Some of the benefits of SAW are:
It has a high deposition rate and efficiency.
It produces smooth and clean welds with no spatter or smoke emission.
It can weld thick materials with deep penetration.
It can be welded in flat or horizontal positions.
Some of the drawbacks of SAW are:
It requires a flux and a wire feeder.
It produces slag that needs to be removed after welding.
It may cause porosity if the flux is contaminated or moist.
It may cause cracking if the weld metal is too hard or brittle.
7. Electroslag Welding (ESW)
Electroslag welding (ESW) is a type of arc welding that uses a consumable wire electrode and a molten slag that covers the arc and the weld pool from atmospheric contamination. ESW can be used for welding various metals and alloys, such as carbon steel, stainless steel, nickel, and hard-facing. ESW is suitable for high-speed production, automation, and thick materials.
Some of the benefits of ESW are:
It has a very high deposition rate and efficiency.
It produces smooth and clean welds with no spatter or smoke emission.
It can weld very thick materials with deep penetration.
It can weld in a vertical position.
Some of the drawbacks of ESW are:
It requires a flux and a wire feeder.
It produces slag that needs to be removed after welding.
It may cause porosity if the slag is contaminated or moist.
It may cause cracking if the weld metal is too hard or brittle.
8. Electrogas Welding (EGW)
Electrogas welding (EGW) is a type of arc welding that uses a consumable wire electrode and a shielding gas that protects the arc and the weld pool from atmospheric contamination. EGW can be used for welding various metals and alloys, such as carbon steel, stainless steel, nickel, and hard-facing. EGW is suitable for high-speed production, automation, and thick materials.
Some of the benefits of EGW are:
It has a high deposition rate and efficiency.
It produces smooth and clean welds with no spatter or slag.
It can weld thick materials with deep penetration.
It can weld in a vertical position.
Some of the drawbacks of EGW are:
It requires a shielding gas and a wire feeder.
It may cause porosity if the shielding gas is contaminated or insufficient.
It may cause cracking if the weld metal is too hard or brittle.
9. Atomic Hydrogen Welding (AHW)
Atomic hydrogen welding (AHW) is a type of arc welding that uses two non-consumable tungsten electrodes and a hydrogen gas that dissociates into atomic hydrogen at high temperatures. The atomic hydrogen recombines at the weld pool, releasing heat and protecting the arc and the weld pool from atmospheric contamination. AHW can be used for welding various metals and alloys, such as carbon steel, stainless steel, aluminum, titanium, copper, and nickel. AHW is suitable for high-quality welding, precision work, thin materials, and complex shapes.
Some of the benefits of AHW are:
It has very high energy density and penetration.
It produces smooth and clean welds with no spatter or slag.
It can weld thin materials without distortion or burn-through.
It can weld dissimilar metals or alloys.
Some of the drawbacks of AHW are:
It has a low deposition rate and efficiency.
It requires high skill and equipment costs.
It requires a hydrogen gas and a filler material (optional).
It is sensitive to wind and drafts.
10. Carbon Arc Welding (CAW)
Carbon arc welding (CAW) is a type of arc welding that uses two non-consumable carbon electrodes and an air or gas shield that protects the arc and the weld pool from atmospheric contamination. CAW can be used for welding various metals and alloys, such as carbon steel, stainless steel, aluminum, copper, and nickel. CAW is suitable for high-quality welding, precision work, thin materials, and complex shapes.
Some of the benefits of CAW are:
It has high energy density and penetration.
It produces smooth and clean welds with no spatter or slag.
It can weld thin materials without distortion or burn-through.
It can weld dissimilar metals or alloys.
Some of the drawbacks of CAW are:
It has a low deposition rate and efficiency.
It requires high skill and equipment costs.
It requires an air or gas shield.
It is sensitive to wind and drafts.
11. Stud Arc Welding (SAW)
Stud arc welding (SAW) is a type of arc welding that uses a consumable stud electrode and a shielding gas that protects the arc and the weld pool from atmospheric contamination. SAW can be used for welding various metals and alloys, such as carbon steel, stainless steel, aluminum, copper, and nickel. SAW is suitable for high-speed production, automation, and thick materials.
Some of the benefits of SAW are:
It has a high deposition rate and efficiency.
It produces smooth and clean welds with no spatter or slag.
It can weld thick materials with deep penetration.
It can weld in a vertical position.
Some of the drawbacks of SAW are:
It requires a shielding gas and a stud feeder.
It may cause porosity if the shielding gas is contaminated or insufficient.
It may cause cracking if the weld metal is too hard or brittle.
In conclusion, arc welding offers a wide range of techniques that cater to different applications and benefits. Each type of arc welding has its unique features that make it suitable for specific tasks. Understanding these types will help you choose the right method for your welding needs. If you want to buy ideal arc welders, the article Arc Welding Tools and Equipment List a How to Select and Use an Arc Welding Power Source? may give you some tips.
