Different Types of

Welding Processes
Abbreviation Full Name Description Best Use Cases Critical Considerations

GMAW / MIG Gas Metal Uses a wire electrode Welding sheet metal Transfer mode affects
Arc Welding and shielding gas. and thick sections, large characteristics and
It’s used for welding groove filling, general application. Must use
stainless steel, copper, fabrication. Most welding shielding gas. Multiple
nickel, carbon steel, and applications in most gas options for varying
aluminum. industries. results and costs. Easy
to learn. The easiest
Also, to replace TIG
process to automate.
where possible. With the
Exceptionally versatile.
right system, MIG can
produce TIG-like welds.

GTAW / TIG Gas Tungsten Uses a non-consumable High-quality, critical Slow travel speed.
Arc Welding tungsten electrode and welds requiring high The most difficult
a shielding gas. It’s used precision and purity. arc welding process
for welding aluminum, (high-value industries to master. Must use
magnesium, copper, like semiconductors, shielding gas. Can
copper alloys, nickel aerospace, marine, induce too much heat
alloys, and stainless steel. petrochemicals, etc.) and have a wide HAZ.
Tungsten selection
and shape affect
characteristics.

PAW Plasma Arc Similar to TIG, but Same as TIG, but with Lift/touch start is not
Welding the torch has two better weld quality. possible, only HF start.
nozzles: one constricts Many PAW variables
the arc and isolates must be set right. It’s
the electrode in an a complex process to
orifice gas, the other use. Arc can’t be easily
provides the shielding deflected due to high
gas separate from stiffness, leading to
the electrode. By better stability.
constricting the arc with
a tight orifice, PAW has
many advantages over
TIG.

SMAW Shielded Commonly known as Outdoor welding in Slower than FCAW/MIG.

Metal Arc stick welding, it uses a adverse conditions. Produces slag. Produces
Welding consumable electrode Pipeline welding and material waste due to
or Stick coated in flux. This type structural steel. Indoor/ discarding the unused
Welding of welding is used to join outdoor welding where part of the electrode.
steel, cast, ductile iron, joints are difficult to There are hundreds of
nickel, or copper. access with other AWS-classified stick
processes. Stick rod is rods you can use. It’s
long and can even be exceptionally versatile.
bent to access the joint.

FCAW Flux Cored Similar to MIG, but uses To replace the stick Produces slag (even gas-
Arc Welding flux-cored electrodes as welding process (self- shielded FCAW). Runs
a filler material for the shielded FCAW) in hotter than MIG and
weld. They can be self- outdoor welding, and can burn through sheet
shielded (no need for a for gaining additional metal. You can use some
shielding gas) or gas- deposition with gas- wires with 100% CO2 gas
shielded (require gas). shielded FCAW. Used in to cut gas costs. Can’t
shipbuilding, structural weld aluminum. Some
steel, bridge building, wires can’t be used for
and pipe welding. all-position welding.

SAW Submerged Type of arc welding that Heavy-duty welding of Granular flux can
Arc Welding uses an electrode that very thick structural steel significantly impact
acts as the filler material. or pressure vessels. the weld and should be
The weld zone is entirely selected for the used
covered with a layer of wire. Multi-wire Sub-arc
granulated flux, hence can drastically boost
the term "submerged" in deposition rate.
the name.

ESW Electroslag Produces metal Single-pass welding of Extremely high metal

Welding coalescence through thick plates in vertical deposition and speed.
molten slag melting the or above 45-degree Preheating isn’t typically
filler metal and the base positions. required. No spatter.
material. The arc only 100% deposition
exists at the beginning efficiency. Can only be
of the process. It’s soon used for carbon steel
extinguished, letting the and some stainless
molten slag conduct steels. Can’t be used on
electricity and fuse the materials thinner than
metal. 1/2-inch.

EGW Electrogas Uses a solid or a flux- Vertical welding of 1/2 to Requires backing.
Welding cored wire, with or 1-1/2-inch thick plates. Challenging process to
without a shielding gas, learn. High heat input
with backing shoes can negatively affect the
(dams) to retain the weld zone.
molten metal.

EBW Electron Uses a beam of high- Applications where Can make shallow
Beam velocity electrons in maximum weld quality or extremely deep
Welding a vacuum to weld is needed. Aerospace, autogenous welds.
materials. Can also be nuclear, and similar Nonvacuum welding can
used in a nonvacuum industries. require a shielding gas.
environment with a
shielding gas.

LBW Laser Beam Works by sending a High-quality welds on Non-contact process.

Welding highly focused beam of thinner materials. High welding speed.
light (laser beam) to the Requires very accurate
metal, causing it to melt joint fit-up. Mostly
and fuse with or without limited to sheet metal
the filler metal. and low thicknesses.
Aluminum, copper, and
similar reflective metals
are challenging to weld.
Equipment and fixturing
costs are high.

FW Friction A solid-state process that High-volume production No filler metal. Typically

Welding fuses the two metals by and dissimilar metal no need for shielding
rotating or moving them welding in critical gas of fluxes. High weld
relative to one another industries like aerospace. quality. High equipment
with surface contact, cost. Part alignment for
causing friction between FW can be difficult.
the two to melt and weld
them together.

RSW Resistance Two electrodes clamp Sheet metal work, cans, There are many electrode
Spot or Seam sheet metal, causing containers, various shapes, including
Welding the spot or seam weld automobile parts. wheels, cylinders,
to form as a result of clamps, and others.
electrical flow resistance. Electrodes wear with
Electrodes apply force use. Complex equipment
prompting the materials maintenance. Costly
to fuse together. equipment.

SW Stud Welding This process uses a stud For efficient stud Portable equipment.
gun to weld studs onto welding. Typically Extremely fast. Can
metal surfaces. Can be used for shear studs weld almost all stud
used with or without a in construction, ship’s shapes. Sometimes
shielding gas. decking, insulation pins, requires using a ceramic
and similar applications. shielding ferrule.

Oxyacety- Gas Uses a flame produced Repair welding when High explosion and fire
lene Welding / by oxygen and acetylene other processes aren’t hazard. Requires high
Oxyacetylene to weld metals. suitable. operator skills. Relatively
Welding low travel speed. It’s
not limited by electrical
power availability. Ideal
for fieldwork.

TW Thermite Thermite welding uses For field welding. Very dangerous process.
Welding a thermic reaction Railtrack welding, and Operators must be
between aluminum and ship, mill, and mold well-trained to deal
a metal oxide (typically repairs. with thermal chemical
iron oxide). Once these reactions. No need for
two are mixed, an additional power sources.
extreme amount of
energy is released, and
so is the filler metal.

CW Cold Welding Solid-state welding, Wire welding, sealing Fast and produces high
where pressure fuses the containers with weld quality. No liquid
two metal pieces. flammable/explosive metal phase. Limited to
substances, and welding specialized applications.
in environments
where arc or flame are
hazardous.

AHW Atomic Type of arc welding. It Largely obsolete. An early Not widely used.
Hydrogen uses an arc between arc welding process. Equipment may be
Welding two electrodes made of Can be used to weld difficult to source.
tungsten with hydrogen tungsten as it’s hot Extremely hot, requiring
gas. enough. more operator care.

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