Welding is the permanent joining of two or more metal parts by applying heat, pressure or both. Dozens of welding processes are used in industry, each suited to different materials, thicknesses, production rates and quality requirements. Choosing the right process directly determines both the cost and the service life of the welded part.
Welding processes are identified internationally by reference numbers in the EN ISO 4063 standard. For example, 111 denotes manual metal arc (covered electrode) welding, 135 MAG welding and 141 TIG welding. These numbers are also used on WPSs and welder certificates.
Types of Welding: The Main Groups
Welding processes fall into two main groups:
- Fusion welding: The joint area is melted, with filler metal added if required. Arc, gas and beam welding belong to this group.
- Pressure welding: The parts are joined under pressure, usually with heating. Resistance (spot), friction and friction stir welding belong to this group.
1. Manual Metal Arc Welding (MMA / Stick, 111)
Commonly known as "stick welding" or "electric arc welding". An arc is struck between a covered electrode and the workpiece; as the coating melts it produces shielding gas and slag. The equipment is simple and portable, and it can be used outdoors and in windy conditions. However, productivity is low and slag must be removed after each electrode. It is widely used for site erection, maintenance and repair, and pipelines.
2. MIG/MAG Welding (Gas Metal Arc Welding, 131/135)
Carried out with a continuously fed wire electrode and a shielding gas. Thanks to its high productivity, ease of automation and wide range of materials, it is the most common process in industrial fabrication. When an active gas (Ar/CO₂) is used it is called MAG; with an inert gas (argon) it is called MIG. For details, see our MIG/MAG welding guide.
3. Flux-Cored Arc Welding (FCAW, 136/138)
Similar to MIG/MAG, but the wire contains a flux (core). It offers high deposition rates and good positional capability, and is preferred for heavy-section structural steel and heavy machinery fabrication. See flux-cored arc welding.
4. TIG Welding (known in Turkey as "Argon Welding", 141)
Carried out with a non-consumable tungsten electrode and argon shielding gas. It produces the cleanest and most precise welds of any process and is preferred for stainless steel, aluminium and thin sheet. It is slow and requires a highly skilled welder. Details: what is TIG (argon) welding?
5. Submerged Arc Welding (SAW, 121)
The arc burns beneath a layer of granular flux and is not visible from outside. It provides very high deposition rates and deep penetration, making it ideal for long straight seams on thick plate, pressure vessels, beams and pipe fabrication. See submerged arc welding.
6. Oxy-Acetylene (Gas) Welding (311)
Carried out with a flame produced by burning oxygen and acetylene. In industrial production it has largely been replaced by arc welding processes, but it is still used for repairs, thin sheet and brazing.
7. Laser and Electron Beam Welding (52, 51)
A concentrated energy beam produces very narrow, deep welds. Because heat input is low, distortion is minimal. It is used in automotive, electronics and precision component manufacturing; the equipment investment is high.
8. Spot (Resistance) Welding (21)
Two sheets are clamped between electrodes and joined at discrete points by passing a high current through them. No filler metal is required. It is the standard in high-volume sheet metal production such as automotive body manufacturing and white goods.
9. Friction and Friction Stir Welding (42, 43)
Heat is generated by rubbing the parts against each other; the material joins without melting. Friction stir welding (FSW) provides high-quality joints, particularly in aluminium panels and in the rail and aerospace sectors.
Welding Process Comparison Table
| Process | Speed | Weld Quality | Typical Use |
|---|---|---|---|
| Stick (111) | Low | Medium–Good | Site work, maintenance, pipe |
| MIG/MAG (131/135) | High | Good | General fabrication, chassis, structural steelwork |
| Flux-cored (136/138) | Very high | Good | Thick sections, heavy machinery |
| TIG (141) | Low | Very good | Stainless, aluminium, root passes |
| Submerged arc (121) | Very high | Very good | Thick plate, pressure vessels |
| Laser (52) | High | Very good | Precision and high-volume parts |
| Spot (21) | Very high | Good | Sheet metal bodies, series production |
How to Choose the Right Type of Welding
- Material: Carbon steel, stainless steel, aluminium and high-strength steel each call for different processes.
- Thickness: TIG or pulsed MIG stand out for thin sheet; MAG, flux-cored or submerged arc for thick sections.
- Welding position: Some processes are better suited to overhead and vertical positions. See welding positions.
- Quantity and repeatability: In series production, robotic MAG or spot welding reduces cost.
- Quality requirements: The EN 1090 execution class (EXC), the EN ISO 5817 quality level and the NDT rate all influence process selection.
At ArmaWeld: Depending on the project, we apply MAG, TIG, flux-cored and robotic welding processes under approved WPSs. The process is selected on the basis of our welding engineer's assessment of the material and quality requirements. For service details, visit our welding processes page.
Frequently Asked Questions
How many types of welding are there?
The EN ISO 4063 standard assigns reference numbers to more than a hundred welding and allied processes. The most common in industry are manual metal arc (111), MIG/MAG (131/135), flux-cored (136), TIG (141), submerged arc (121), laser (52) and spot (21) welding.
Which type of welding is the strongest?
There is no single "strongest" process. Any process applied with the correct WPS and a qualified welder can achieve the strength of the parent metal. The process is chosen according to material, thickness and position.
What is the difference between MIG/MAG welding and TIG (argon) welding?
In MIG/MAG welding the wire electrode melts and becomes the filler metal; it is fast. In TIG (argon) welding the tungsten electrode does not melt and filler is added separately; it is slower but cleaner and more precise.
The Right Welding Process for Your Project
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