AW, GMAW, GTAV, SMAW, SAW… The abbreviations may be similar but the actual welding processes aren’t. If you’re confused between the common types of welding or wondering which welding process is right for you, this is the guide for you. And no matter which welding process you use, always make sure to abide by welding safety standards to keep yourself injury-free.
| FCAW | GMAW | GTAW | SMAW | SAW | |
| Also Known as | – | MIG | TIG | Stick | – |
| Wind | Suitable under 5 MPH | Not Recommended | Not Recommended | Suitable under 10 MPH | Suitable under 10 MPH |
| Common Applications | Stell allows, iron | Steels and aluminum | Versatile (ferrous and non-ferrous) | Steel alloys, cast iron | Low carbon and Low alloy steels |
| Ease of Usage | Moderate | Easy | Hardest | Easy | Moderate |
| Shielding Gas | Not Required | Required | Required | Not Required | Not Required |
1. What is Flux Cored-Arc Welding (FCAW)?
Flux cored-arc welding or FCAW is a type of semi-automatic welding process that uses an arc between the consumable electrode or filler wire and the metal workpiece. The heat from the arc melts both the filler and the workpiece, fusing them together and filling any gaps (if present).
Flux-cored arc welding is very similar to GMAW or MIG welding with one key difference – the electrode in FCAW is shielded by the flux core (removing the need for a shielding gas) which protects the electrode from the wind and the air. FCAW also enables higher wire deposition rates and greater arc stability which makes it a better alternative for welding alloys than MIG.
That said, MIG and FCAW are so similar that FCAW is often considered a part of MIG or GMAW and both processes can be carried out with nearly identical equipment. FCAW is a highly productive welding process and can be used on metals like plain carbon, alloy, stainless and duplex steels and the ability to use this process outdoors in windy conditions makes it a very versatile welding process.
FCAW is also a relatively easy manual welding process and can be used to make a lot of high-quality welds quickly.
2. What is Gas Metal-Arc Welding (GMAW)?
Gas Metal-Arc Welding (GMAW), also popularly known as Metal Inert Gas (MIG) is a welding process that’s easy to learn and offers high productivity. Similar to FCAW, GMAW processes use a consumable electrode (a filler wire) to weld metal pieces together with an arc generated by a DC power supply. All GMAW welding processes use a shielding gas but the type of gas differs.
MIG is the more popular GMAW process in the US and stands for Metal Inert Gas which means it uses inert gasses like argon and helium, making it suitable for welding non-ferrous metals like aluminum.
MAG, on the other hand, stands for Metal Active Gas and hence uses mixtures of carbon dioxide, argon, and oxygen as the shielding gasses. MAG is more suitable for welding steel.
MIG is one of the most popular welding processes in the United States because it offers incredible versatility and is relatively easy to use. However, the level of manual skill required can vary greatly between models and configurations (MIG can be manual, semi-automatic, or an automatic process). It also requires more routine maintenance than GTAW and SMAW.
3. What is Gas Tungsten-Arc Welding (GTAW)?
Gas Tungsten-Arc Welding (GTAW) is also known as Tungsten Inert Gas (TIG) welding that, unlike GMAW and FCAW, uses a non-consumable electrode made out of tungsten, meaning a separate filler wire or rod may be required. GTAW or TIG is a versatile welding process that can be used on both ferrous and non-ferrous metals, with or without a filler.
Compared to other welding processes, GTAW or TIG has a steeper learning curve and is the hardest to master because GTAW offers less control over arc and weld pool behavior. It’s still very popular because the welds created through GTAW or TIG welders are of very high quality, precise, and very durable. The small arc also makes it suitable for work on thin metals and mold repair.
Learn more about the differences between MIG and TIG welding.
4. What is Shielded Metal-Arc Welding (SMAW)?
Shielded Metal-Arc Welding (SMAW) or Stick Welding is a manual welding process that is very similar to FCAW – the main difference being that the entire electrode is coated with an inert gas (flux) in SMAW whereas in FCAW the flux is only at the core of the electrode.
The key advantages of SMAW are its flexibility, simplicity, and cost. Welders require minimal equipment to get started and while the manual process does require some training, SMAW is far more forgiving and easy on beginners.
Infographic on how Shielded Arc Welding (SMAW) Works from PrimeWeld – Link to Beginner’s Guide on SMAW)
5. What is Submerged-Arc Welding (SAW)?
Submerged-Arc Welding (SAW) is a semi-automatic or automatic welding process used for welding thick metal sheets or when long welds are required. The workpiece is submerged under a layer of powdered flux creating a protective shield (separate shielding gas is not required).
SAW is an extremely efficient welding process with thermal efficiency as high as 60%, no toxic metal fumes, or weld splatters. The automatic tractor-type machines used for SAW are usually found in heavy industries like shipbuilding, rail-road, pipe building, etc.
6. What is Laser Welding
Laser welding is a precision welding technique that uses a high-intensity laser beam to join metal or thermoplastics. The process involves focusing a laser beam on a small, precise area, allowing the material to melt and fuse together as it cools, creating a strong weld. This method is known for its high welding speeds, deep penetration, and minimal heat input, which results in less distortion of the workpiece compared to traditional welding methods. Laser welding is widely used in various industries, including automotive, aerospace, and electronics manufacturing, due to its ability to produce high-quality welds in both thin and thick materials. It’s particularly valued for its capability to perform complex welds in difficult-to-reach areas and for delicate applications that require high precision.
Welding Types Were Developed Over the Decades
These types of welding processes were developed over many decades for a specific reason and to achieve a specific outcome. This article highlights the different advantages each process has to offer and should help you choose the right welding process.