Arc Welding vs. Laser Welding: Pros, Cons & Applications

Arc welding, a remarkably versatile metal joining process, has been used for centuries. The term encompasses a range of methods that harness the heat of an electric arc to melt and fuse the pieces, including MIG, Stick, and TIG welding.

However, we are living in a world of innovations and technological advancements, so new techniques are emerging. Laser welding, a widely adopted procedure, is making its mark. As the name suggests, a series of methods use the heat of the laser to melt and fuse the pieces.

In this article, we will explore and further explain the differences between arc welding and laser welding, including their pros, cons, and applications.

TIG Welding vs. Laser Welding
Photo by @igor.welder7 (TikTok)

Basics Of Arc Welding

Arc welding is a term that denotes dozens of welding methods that use the heat of an electric arc to melt and fuse filler metal (if applicable) and base metal. The arc forms between an electrode connected to one side of the terminal (either + or -) and a base metal attached to a ground clamp (work clamp).

Arc Welding Explained
Source: https://www.perfectwelders.com/arc-welding-the-5-welding-processes-you-need-to-know/

Once you press the trigger or move the electrode close enough to the base metal, the electrical circuit closes. The arc jumps from the electrode to the base metal, and its heat melts and fuses the pieces. Molten metal creates a weld pool, and once everything solidifies, you get a weld.

Depending on the process, the molten weld puddle is protected by an external shielding gas or flux. Molten metal tends to pick up contamination and atmospheric gases, creating small holes known as porosity. An external shielding gas or molten layer of flux protects the weld bead as it cools, yielding uniform and solid welds.

Know the difference: Many welders use the term Arc welding when talking about Shielded Metal Arc Welding (SMAW) or Stick/Arc welding. While this is a widely accepted phrase, Arc welding indicates all welding methods that use the heat of an arc. The most common examples are Gas Metal Arc Welding (GMAW/MIG), Gas Tungsten Arc Welding (GTAW/TIG), Flux Cored Arc Welding (FCAW), and the noted Shielded Metal Arc Welding (SMAW/Stick).

4 Main Types of Arc Welding 
Source: https://www.mechdaily.com/types-of-welding/

Applications of Arc Welding

Welders worldwide use Arc welding in various industries due to its versatility, strength, and cost-effectiveness. Some typical applications include the following:

• Metal fabrication: Welders prefer arc welding when creating metal structures, heavy machinery, and equipment.

• Construction: Arc welding is crucial in joining structural steel in buildings, bridges, and other infrastructure projects.

• Shipbuilding: Many find arc welding essential for assembling and repairing ships, offshore structures, and marine equipment.

• Pipeline and Oil & Gas Industry: Arc welding is spread in the fabrication and maintenance of pipelines, storage tanks, and drilling equipment.

Pipeline Welding
Source: https://www.uti.edu/blog/welding/pipeline-welder

• Repair and Maintenance: Welders apply arc welding in workshops and field repairs for machinery, tools, and metal structures.

• DIY, Home, and Hobby applications: A big part of arc welding finds its use in DIY projects, home, and hobby applications and repairs.

• Automotive: Essential for assembling vehicle frames and body parts, exhaust systems, and other metal components.

• Railway Industry: Utilized to weld train components, tracks, and repair work.

Railway Welding
Source: https://bemorail.com/rail-technology/rail-welding/

Advantages of Arc Welding

Arc welding offers several advantages that make it a popular choice in various industries. Some of the key benefits of Arc welding include the following:

Outdoor Stick Welding Repair
Photo by @toolgirlsgarage (IG)

Cost-efficient: Investing in Arc welding equipment usually requires a lower initial investment. It is generally more affordable and straightforward than laser welding or any state-of-the-art, automated methods.

Versatile: Arc welding works excellently with various metals, including mild steel, stainless steel, aluminum, and different non-ferrous and exotic metals. Additionally, its versatility makes it a valuable part of many industries worldwide.

Easy to use and implement: Many find traditional welding very easy to use, learn, and implement in production. Workers in conventional construction and fabrication often prefer arc welding over other methods due to ease of use.

Portability: Most new inverter welders, such as the YesWelder Arc 205DS Pro, are portable, allowing you to carry them to various locations or around the shop and garage.

Produces strong and durable welds: Arc welding produces high-strength joints that can withstand heavy loads and harsh conditions. This is particularly important in medium and thick pieces, where methods such as Stick welding shine.

Ability to work in various welding positions: Depending on the arc orientation, welders can work in flat, horizontal, vertical, and overhead positions as needed.

Stick Welding in Overhead Position 
Photo by @datboimiggz (TikTok)

Disadvantages of Arc Welding

Despite the advantages, arc welding also has some limitations. The most notable drawbacks of arc welding are the following:

Wide heat-affected zone (HAZ): Arc welding produces a wide HAZ. Lack of heat control can cause thermal distortion or warping in thin, heat-sensitive metals.

Safety risks: Traditional welding is hazardous. The arc produces high heat and radiation, which can damage your eyes or skin. Burning the flux or melting layered metals creates toxic fumes that can harm welders or the environment.

Longer learning curve: Producing the highest-quality welds requires extensive experience and skills. While little to no experience is necessary for home repairs or projects, it takes time to master the technique and expertise needed to produce crucial welds.

Limited precision: Manual arc welding is less precise in critical applications. Unless automated, it can be challenging to produce repetitive welds.

Limited aesthetics: Although TIG welding can produce some of the most visually pleasing welds, not all techniques provide these opportunities. Arc welding often causes slag and spatter, which take time to clean and affect the overall weld appearance.

Some techniques are slow: Manual arc welding methods such as TIG or Stick welding are often slow. Taking more time to fill the joint and finish the weld increases the overall welding costs.

TIG welding is slower due to its precision and control.
Photo by @dahmesofficial (TikTok)

Basics Of Laser Beam Welding (LBW)

As the name suggests, laser welding uses a laser (Light Amplification by Stimulated Emission of Radiation) to melt and fuse metals or thermoplastics. Instead of an arc, a concentrated and focused beam of light melts and fuses the pieces.

Principle of Laser Welding Between Two Workpieces
Source: https://www.researchgate.net/figure/Principle-of-laser-welding-of-two-workpieces-The-laser-welding-parameters-are-laser_fig1_367621213

A gas, solid, or liquid as a medium extracts laser beams. Several types of laser are used in laser welding. Most commonly, they are divided into gas lasers or solid-state lasers. Gas lasers use gases such as CO2, and solid-state lasers use ores such as yttrium, aluminum, and garnet (YAG and Nd: YAG lasers). Mirrors or fiber optics direct the laser beam to the weld joint.

Authentic laser beam welding is a fusion method that doesn't use additional filler metal. Instead, a narrow and precise beam of light melts the edges of the seam, fusing them. This yields a minimal heat-affected zone (HAZ).

Precision and heat control make laser welding ideal when joining thin sheets and applications that require ultimate precision. The process is fast, allowing welders to finish the project quickly.

Laser welding is ideal for thin sheets due to its precision and heat control.
Source: https://www.thefabricator.com/thefabricator/article/laserwelding/using-hand-held-laser-welder-technology-for-manual-welding

Applications of Laser Welding

Welders today use Laser welding in industries that require precision, high-speed processing, and minimal heat-affected zones. Some typical applications include:

• Automotive industry: Laser welding produces precise, fast, and repetitive welds on thin metal body components, engine parts, and exhaust systems. The process works great with lightweight materials like aluminum and high-strength steel, which are widely used in the car-making industry.

Laser Welding in the Automotive Industry 
Source: https://www.hg-star.com/laser_processing_in_automotive_manufacturing/

• Aerospace industry: Welders use lasers in the aerospace industry to join thin, heat-sensitive materials for various aircraft structures, such as spaceships and airplanes.

• Medical device manufacturing: Welders use laser welding to build surgical instruments, pacemakers, and implants. The laser's precision is ideal for small, delicate components used in medical electronics.

• Electronics and microelectronics: Precision, speed, and high-quality laser welding are ideal for battery components, connectors, and circuit boards. Welders also use lasers in semiconductor and sensor manufacturing.

Laser Welding in the Electronics Industry
Source: https://amglo.com/how-laser-welding-benefits-the-electronics-industry/

• Nuclear and solar energy: Lasers produce airtight, high-quality welds for fuel cells, solar panels, and nuclear reactor components.

• Jewelry and watchmaking: Laser welding is ideal for the repair and fabrication of intricate jewelry and watch parts.

Laser Welding for Jewelry and Watchmaking
Source: https://dplaser.com/how-to-use-a-laser-welder-for-jewelry/

Advantages of Laser Welding

Laser welding offers several advantages over traditional welding methods, making it ideal for precision applications. Some key benefits include:

High precision: The focused laser beam is extraordinarily precise, making it suitable for delicate, miniature, and intricate components. The welds are almost invisible but strong and reliable.

Narrow heat-affected zone (HAZ): A highly concentrated laser beam is focused on a small area, yielding a narrow heat-affected zone (HAZ). Narrow HAZ reduces heat impact and exposure, which is crucial in avoiding distortion or warping on thin metal sheets and delicate metals. The mechanical qualities of the underlying material are preserved.

Narrow HAZ of Laser Welding
Source: https://photonweld.com/

Fast welding speed: Lasers are much quicker than traditional arc welding methods, especially on thin pieces. Concentrated energy promotes speedier heating and cooling, resulting in shorter cycle duration and higher overall efficiency. Faster processing speed results in higher production and swifter turnaround.

Produces high-quality welds: Laser welding is a non-contact welding method that makes clean, smooth, and spatter-free welds. No physical contact between the welding tool and the material reduces wear and contamination. These attributes yield aesthetically beautiful welds with low surface flaws, making them ideal for applications requiring a clean appearance.

Image of Laser Welds
Source: https://www.youtube.com/shorts/58h4Au4lAYw

Versatile: Laser welding is an adaptable method capable of producing narrow and deep welds. It can weld various metal types, thermoplastics, and dissimilar metals.

Easy to automate: Laser beam welding is simple to integrate into robotic systems. Lasers are also open to automation and integration into production lines, making them ideal for medium—to large-scale production and repetitive welds.

Automatic Robotic Laser Welding
Source: https://qviro.com/blog/robot-welding-cost/

Disadvantages of Laser Welding

Although advantageous in many applications, laser welding also presents some drawbacks. The most notable disadvantages of laser welding are the following:

Laser Welding Process
Source: https://www.youtube.com/watch?v=qvqXjy9CciA

High initial costs: Laser welding equipment is more complex and expensive than traditional welding equipment. Although it pays off due to higher welding speed and less rework, you'll have to justify the costs for your needs.

Limited penetration: Most lasers produce a limited amount of heat, which cannot reach temperatures that the arc creates. As a result, lasers usually come short when welding thick stock.

Requires trained operators: Although most laser welding is automated or semi-automated, operating and maintaining the equipment requires technical expertise. Thus, operators need specialized training to program and work with laser welding equipment.

Source: https://www.wctc.edu/WCTC/Academics/Continuing-Education

Limited accessibility: Lasers require precise alignment and clean surfaces for high-quality welds, making pre-weld preparation crucial. Additionally, welding complex pieces and certain joint configurations in specific positions can be challenging.

High maintenance costs: Optical components like lenses and mirrors require regular maintenance and replacement. Frequent maintenance increases operational costs.

Reflectivity issues: Highly reflective metals like aluminum, copper, and gold can reflect laser beams, reducing their efficiency. Addressing the problem requires specialized settings.

Arc Welding vs. Laser Welding: Key Differences And Comparison Table

How to Choose the Right Welding Technique for Your Projects?

Both arc and laser welding have their ups and downs, so you might still be wondering which is the right one for you. To make an informed choice, you should consider several key factors that concern your welding projects. Most importantly, you should consider the following:

• Type of projects

• Equipment setup

• Welding costs

• Weld quality and specifications

Let's discuss more.

Source:https://www.youtube.com/watch?v=GFM4dYnXaTU&t=17s

Welding Project Complexity

Arc welding is ideal for straightforward, heavy-duty industry or home projects. These involve welding or repairing medium-thickness or thick parts of steel around the house or in industries such as construction or general metal fabrication.

Arc welding thrives outdoors, in harsh conditions, or in various welding positions. If you need a cheap technique for simple home projects or metal fab shops, arc welding is your go-to choice.

Meanwhile, laser beam welding is an excellent welding technique for complex, intricate designs and precision work. Its focused laser beam yields controlled HAZ and heat, which is ideal for thin pieces and exotic and heat-sensitive metals.

By tightly focusing the beam, laser welding avoids the thermal distortion and weld defects caused by extensive heat exposure on the welded pieces. That's why it is often used in state-of-the-art work such as aerospace, nuclear, or microelectronics.

Laser Welding for Aerospace Applications
Source: https://fsmdirect.com/acing-aerospace/

Equipment Setup and Initial Investment

Arc welding uses straightforward and cheap equipment that is easy to set up, install, and maintain. Home welders, such as the FIRSTESS MP200 5-in-1 Welder & Cutter, cost less than $1000 and will cover most of your needs. Industrial-grade welders are more expensive but cheaper than laser welding equipment.

FIRSTESS MP200 5-in-1 Welder & Cutter

Laser welding equipment, on the other hand, is more complex and specialized than arc welding equipment. The process is managed by a control system, which adjusts the laser power, beam intensity, and other parameters.

As a result, laser welding systems are pricier than $10,000, and some advanced equipment can even cost $100,000. The initial investment is five to ten times higher, and you should also consider higher maintenance, consumables, and part costs.

Laser Beam Welding 
Image by: anek.soowannaphoom/Shutterstock.com

Welding Cost Justification

Keep in mind that initial investment accounts for only a small portion of overall welding costs. To make the right choice, you should also consider the other parts of welding costs.

Arc welding provides better value for small home shops that work on straightforward welding projects. Even if you do it regularly, the arc welder will pay for itself quickly, and overall costs are not that high.

However, cost justifications start to make sense in large-scale welding operations. Laser welding's high welding speed and repetitive welds with little to no rework save money as a long-term investment. Although the initial investment is high, laser welding equipment is future-proof, and its easy automation makes it excellent for long-term cost cuts.

Laser welding is ideal for high-speed and repetitive welding.
Source: https://blog.hirebotics.com/guide-to-welding-robots

Weld Quality and Specifications

Arc welding methods such as TIG welding can produce beautiful, high-quality welds. However, flux processes can create spatter and slag. In general, all arc welding methods are often used for projects that require high-strength, durable welds.

Meanwhile, weld specifications that call for aesthetics, high precision, and minimal distortion often require laser welding. Laser welding produces smooth, uniform, nearly invisible welds, which are frequently desired in industries such as consumer electronics.

Smooth, Uniform, Nearly Invisible Laser Welds
Photo by @igor.welder7 (TikTok)

Hybrid Laser Welding: Combining the Best of Both Worlds

As you can deduce, no welding technique is perfect. Both arc and laser welding have ups and downs, which make them a better choice for one or another application. However, scientists managed to combine the best of both worlds in a welding method called hybrid laser welding.

In hybrid methods such as Hybrid MIG or Hybrid TIG welding, laser welding is used in conjunction with arc welding. Welders harness the advantages of both traditional arc and laser welding while overcoming their drawbacks. Laser welding provides high welding speed and precision, while arc welding contributes to improved penetration and the ability to work on thicker pieces with ease.

Hybrid Laser Welding Explained
Source: https://www.laserline.com/en-int/laser-hybrid-welding/

Final Thoughts

Both arc and laser welding are widely used today, but in somewhat different applications. Arc welding is a straightforward, cheap, and simple method for home and heavy-duty projects.

Laser welding offers precision, high quality, and speed, which are crucial in complex work and on delicate metals. Although equipment is initially costly, it provides more value in long-term, large-scale welding applications.

Therefore, choose a welding method that fits your immediate project requirements. Your choice should also align with your long-term operational goals, workforce capabilities, and budget constraints.