How To Choose The Right Welding Types

Welding is a fantastic metal joining process that produces a strong and everlasting bond between pieces. Due to its versatility and popularity, the industry constantly evolves, so we are seeing various welding types today.

The choice is extensive, from arc welding methods such as MIG, TIG, or Stick welding to resistance and laser welding. As a beginner or a new welder, you might wonder which is the best for you.

In this article, we'll teach you how to choose the right welding types for your projects, including tips, tricks, and comparisons of the most popular welding methods.

Source: https://www.mechdaily.com/types-of-welding/

Types Of Welding Methods

Welding can be diverged into various welding types and welding methods. But fundamentally, we see methods based on the heat source used to melt and fuse pieces. Based on the heat source, welding can be divided into:

• Arc welding (uses the heat of an arc)
• Resistance welding (uses the heat of electrical resistance and pressure)
• Gas welding (uses the heat of gases, typically oxygen and acetylene)
• Laser welding (uses the heat of the laser to melt and fuse pieces)
• Electron-beam welding (uses a beam of high-velocity electrons)
• Thermite welding (uses heat from exothermic reaction)

Source: https://www.adorfon.com/welding-equipment-in-industry/

You will likely use Arc welding types as a beginner, hobby, home, or DIY welder. These methods use the heat of the electric arc to melt the pieces and filler metal or electrode and fuse them.

The four most popular arc welding methods are MIG welding, Stick/Arc welding, TIG welding, and Flux-cored arc welding. Understanding the basics of each method helps you make an informed choice when choosing the suitable welding type for your projects. 

Let's briefly explain each.

Source: https://forestry.com/guides/4-types-of-welding-explained-mig-vs-tig-vs-stick-vs-flux-core/

Gas Metal Arc Welding (GMAW, MIG Welding)

Gas Metal Arc Welding, or Metal Inert Gas (MIG) popularly is one of the most straightforward welding processes. This method uses an electric arc to melt the wire and base metal.

What makes MIG welding easier than other metals is its semi-automated foundation. The MIG welding uses an automatically fed welding wire, which also serves as an electrode. To weld, you press the trigger on the MIG gun and move it across the joint.

MIG welding uses a solid wire that requires external shielding. Shielding gases such as Argon or CO2 create a protective atmosphere that keeps the contamination out of the weld.

Overall, MIG welding is considered one of the easiest types to use. It can work with various metals such as mild steel, stainless steel, or aluminum and medium thickness.

Downhill MIG Welding on 1/16” Carbon Steel
Photo by @sewingwithfirewelding (TikTok)

Gas Tungsten Arc Welding (GTAW, TIG Welding)

Quite opposite to MIG, TIG welding, or Tungsten Inert Gas welding, is considered one of the most complex arc welding methods. However, the high-skill requirements produce some of the highest-quality welds.

TIG welding also uses an electric arc to melt and fuse pieces. But this time, the arc is established between a non-consumable tungsten electrode and base metal. Non-consumable means tungsten does not melt during the welding.

Welders use a separate filler metal known as a TIG rod to fill a join. You hold a torch as a heat source in one hand and manually feed the rod with the other hand. Both tungsten and filler metal require non-reactive, or inert shielding gas to keep the contamination out.

TIG Welding Aluminum
Photo by @americanbackroad (TikTok)

The entire process of dab and move can take a lot of skill, time, and patience to master. However, once fully mastered, TIG welding can produce some of the highest-quality, clean welds. Precise heat control works great with delicate, thin, and exotic metals.

Shielded Metal Arc Welding (SMAW, Stick/Arc welding)

The SMAW is one of the oldest arc welding methods, but welders use it regularly in industrial applications, repairs, and on-field work. Stick welding is the industry's favorite since it allows welders to finish the job quickly and cheaply.

At its core, Stick welding uses self-shielded electrodes to produce the weld. The outside of the electrode is coated with flux. Once it melts, the flux forms a top layer of slag that protects the molten weld from atmospheric contamination. As a result, you don't need external shielding, so you can freely weld outside or in the draft.

Stick Welding Repair
Photo by @miss.weldsd (TikTok)

Like TIG, Stick welding is a manual welding method, often referred to as Manual Metal Arc (MMA welding). Except for the amperage, you manually control all other parameters such as arc length, travel speed, and travel angle. As a result, Stick welding is more skill-demanding than MIG, but not as challenging as TIG welding.

The most significant advantages of Stick welding include low costs, and the ability to weld outside and finish the job quickly. But at the price of somewhat more spatter and lower weld aesthetics.

Source: https://www.youtube.com/watch?v=y-OKi8oSNQ4

Flux Cored Arc Welding (FCAW)

Flux-cored arc welding is a wire welding method and a variant of MIG welding. In its base, FCAW uses the automatically fed wire serving as electrode and filler metal. However, unlike MIG welding, FCAW uses a hollow, flux-cored wire.

The wire itself is filled with flux, that creates a layer of slag and protects a molten weld from atmospheric contamination. Like Stick electrodes, a flux-cored wire allows welders to weld outdoors without external shielding.

In general, FCAW combines the ease of use and foundations of MIG welding, with an ability to weld outdoors. These advantages make the Flux core a highly versatile technique, mostly reserved for thicker metals.

FCAW welding is ideal for thicker metals.
Photo by @eddierodriguez006 (TikTok)

Quick Comparison Of Arc Welding Methods

How To Choose The Right Welding Type

Understanding the foundation of each method can significantly help you make an informed choice for your following project. But, to help you choose the most suitable welding method for your work, we will discuss several factors that can affect your choice.

To perfectly choose the right welding type for the job, you should first consider the following:

• The thickness of the metal you are welding
• Type of metal you are typically welding
• Skill requirements
• Weld quality and aesthetics
• Overall costs of equipment, accessories, and consumables
• Welding speed and productivity
• The environment you are working in
• Welding safety

There is no one-size-fits-all when it comes to welding methods. One method can work better in specific applications and projects, and we will explain each factor more thoroughly.

MIG Welding a Stainless Downpipe
Source: https://www.youtube.com/shorts/ZrDR8LbzdSg

Metal Thickness And Welding Types

The truth is that all methods, including MIG, TIG, Stick, or Flux core welding, will work with medium-thickness metals of around 1/8" and up to 3/16". However, each welding type has limitations regarding the upper or lower end of the metal thickness.

You should use TIG welding for projects that involve welding thin sheet metal 1/16" or thinner. GTAW has precise heat control and a low amp range down to 5 amps, allowing you to avoid distortion, warping, or burn-through. Welding such thin metal often doesn't require a filler metal and gap, resulting in fusion TIG process, or autogenous welding.

TIG Welding 1/16" Mild Steel Vertical Up T-Joint Weave
Photo by @hoodedweld (TikTok)

Welding thick metals, on the other hand, requires high-heat methods such as Stick welding or Flux-cored arc welding. Stick welding can produce high amps suitable for metals thicker than 3/16" or even 1/4" in a single pass. This high heat, combined with larger electrodes or thick flux-cored wire, ideally penetrates through thicker stock.

Type of Metal And Welding Types

As a hobby welder, you are likely to weld mild steel, or occasionally stainless steel or aluminum around your garage or shop. If your projects include welding only mild steel, you can choose any of the four most popular arc welding types. You can successfully weld mild steel with MIG, TIG, Stick, or Flux core welding, so the choice comes down to other factors and personal preferences.

In theory, you can also weld stainless steel with all arc welding methods, but in reality, many recommend MIG or TIG Welding. DC TIG welding works great for thin and highest-quality stainless steel applications. MIG welding provides good heat control, is generally easier to perform, and produces decent results on stainless steel.

TIG Welding Stainless Steel Exhaust
Photo by @datboimiggz (TikTok)

Many consider aluminum one of the most challenging metals to weld. Although Stick welding aluminum is theoretically possible, many prefer to weld it with TIG or MIG welding. AC TIG welding aluminum produces the highest-quality and cleanest welds on thin aluminum. Meanwhile, MIG welding is more manageable and easier to perform, but at the price of weld aesthetics.

Nonetheless, advances such as pulsed MIG and dual pulsed MIG, improved overall heat control and weld aesthetics. With our YesWelder Firstess DP200 Dual Pulse MIG welder, you can now achieve almost TIG-like welds on aluminum.

Firstess DP200 Multi-Process DualPulse™ MIG Welder

Welding non-ferrous or exotic metals such as magnesium, nickel or titanium requires AC TIG welding. The cleaning action of AC welding removes the protective oxide layer and provides excellent heat control, which works great on most metals.

TIG welding Titanium Tubes
Source: https://www.youtube.com/shorts/4plATbkNUgs

Skill Requirements And Welding Types

MIG welding is considered one of the most straightforward and manageable welding methods. Its semi-automated fundamentals make it ideal for beginners and new welders getting into the trade. Thus, if you are looking for an easy and forgiving method, go for MIG welding.

Source: https://weldguru.com/mig-welding/

Many consider Stick and Flux-cored welding somewhere in between in terms of skill requirements. Flux core is somewhat more accessible due to the semi-automated principle, but it still requires some skill. Stick takes some time to master the electrode manipulation, especially when weaving and filling the larger joints.

Welders consider TIG welding one of the most challenging welding methods. It requires immaculate cleanliness, good weld preparation, and technique. The technique requirements include coordinating with both hands and catching the rhythm of precisely and timely feeding the rod into the molten weld puddle.

Source: https://blog.red-d-arc.com/welding/aluminum-welding/aluminum-welding-challenges

Weld Quality And Aesthetics

Although hardest to master, TIG welding produces the highest-quality, cleanest, and visually pleasing welds. Welders use TIG in various critical applications such as aerospace, food and beverage, or nuclear industries, where its quality plays a crucial role. 

You can also get some high-quality results with MIG welding but with lesser weld aesthetics. Although new advances in the form of pulsed and dual pulsed MIG can even produce stacked dimes, MIG still has some spatter that requires post-weld cleaning and can affect the overall appearance.

Due to their high heat, Stick welding and Flux-cored arc welding tend to produce messy welds with excessive and hard spatter. Although the bond is robust and everlasting, the overall appearance of SMAW and FCAW often limits it to applications where weld aesthetics are not paramount.

Source: https://www.youtube.com/shorts/bfsfdSC2m0I

Welding Costs And Welding Methods

Stick welding is considered the cheapest method when considering overall welding costs, including equipment, consumables, and accessories. The ability to produce strong welds at low costs makes Stick welding the industry's favorite. Small Stick welders such as a YesWelder ARC205DS can cover most home or farm applications and repairs, but they won't break the bank.

ARC-205DS-PRO Digital Display 110V/220V Stick& Lift TIG In One Stick Welder

MIG welding and Flux core welding share the same platform, and most MIG welders will also support FCAW. While the overall value for the money spent is excellent, MIG welders are somewhat more expensive than Stick machines. There are also some added costs with buying wire, MIG gun consumables, and shielding gas.

TIG welding has the most complex equipment, with the ability to control each step of the welding process, use pulsing, or switch to AC welding on aluminum. Each feature or option improves the overall control and welding performance, but it comes with a price. That's why TIG welders, with torch accessories and consumables, tungstens, optional foot pedal control, external shielding, and added filler rods are the most expensive pieces of equipment.

AC TIG Welding Aluminum
Source: https://www.youtube.com/watch?v=KAhbRRtN5tQ&t=3s

Welding Speed And Productivity

MIG and Flux core welding have high deposition rates, ideal for high-volume production. Automotive companies often fully automate MIG welding to achieve even better productivity and speed. Flux core can be used with dual shielded wire that despite flux requires external shielding to provide even higher deposition rates.

Dual Shielded FCAW Welding
Photo by @datboimiggz (TikTok)

Stick welding is somewhere in between regarding welding speed and productivity. It is not as fast as MIG welding, but low costs of operation compensate for speed, creating a favorably cost-efficient process. But, if you solely look at welding speed and depositions, MIG and FCAW take an edge.

TIG welding is considered the slowest method. It takes time to finish welds, although their quality and lack of post-weld cleaning are unmatched by other methods.

TIG Welding Process and Welds Effect
Source: https://www.youtube.com/shorts/BHXyqKoXgY8

Welding Environment

The choice of welding method can also depend on whether you are working inside or outside. You can weld indoors using any welding method, including MIG or TIG. The wind or draft won't blow away the shielding gas from the puddle and create contamination, so you can weld safely.

Meanwhile, you will need self-shielded processes such as Stick or Flux core welding when welding outdoors. As mentioned, the slag layer protects the molten weld pool from contamination, so you can weld outdoors, or even in harshest conditions.

Stick Welding Outdoors
Photo by @brokeass_wil (TikTok)

Welding Safety

Welding is a hazardous trade with various risks lurking behind every corner. So, it is essential to follow safety precautions and protocol and wear personal protective equipment at all times. When it comes to welding types, some can be more hazardous than others.

For example, Stick welding can produce high amperage or heat. As a result, you will need thicker gloves and a leather jacket to protect yourself from burns. Meanwhile, low-amp TIG welding is not that hot, so you'll need thinner gloves that provide better dexterity rather than protection.

In addition, flux-shielded processes such as Stick or Flux-core welding can produce toxic gases. Although burning metal and filler with any method produces harmful gases, flux can be toxic, so you should always work in a well-ventilated area.

Fumes and Toxic Gases while Stick Welding 
Source: https://mccarthy-environmental.co.uk/working-safely-with-welding-fume-a-summary-of-solutions-and-risks/

Out-Of-Position Welding And Joint Design

When welding in flat or horizontal positions, and butt or T joints, gravity works for you and pulls the molten metal into the joint. You can use any welding type without risking the quality of the welds. Many seasoned welders recommend trying welding in position whenever possible, to reduce the risks of lack of fusion, poor tie-in, or penetration.

However, now and then, you'll have to face out-of-position welding, typically in vertical or overhead positions. In this case, gravity pulls the weld puddle out of the joint, so you must act fast. MIG welding is suitable for out-of-position welding on thin or small pieces, as lower speeds and parameters don't drastically affect productivity. However, FCAW runs hotter, so welders consider it more effective for out-of-position welding.

Overhead FCAW Welding
Photo by @jhernan817 (TikTok)

Stick welding is always a good option for vertical welding, and is often used when welding around pipes in a vertical position. However, because SMAW is slow, welders prefer it for out-of-position applications where welding productivity isn’t as critical.

TIG is also considered an all-position welding method, as TIG rods are not classified by position. However, TIG welding out-of-position can be challenging and demanding.

Overhead TIG Welding
Photo by @michaeltansey53 (TikTok)

Final Thoughts

Be mindful when choosing the suitable welding method for your projects and applications. Before opting for a process, primarily consider its properties, including amperage, metal types, skill requirements, etc.

Although most processes will work weld on medium-thickness mild steel, or indoor, position welding, working with delicate, thin, or thick metals and harsh conditions can be challenging. Therefore, understanding the capabilities of each process is crucial in making an informed choice.

The idea behind the article was to help you understand how each process works in different situations. Only by understanding its pros, you can choose wisely each time, rather than having to consult the online literature.