What Are The 7 Types Of Welding – Choosing The Best Method
The 7 primary types of welding include MIG (GMAW), TIG (GTAW), Stick (SMAW), Flux-Cored (FCAW), Gas (Oxy-fuel), Plasma Arc (PAW), and Submerged Arc (SAW). Each method serves a specific purpose, ranging from simple home repairs to high-precision industrial manufacturing.
Stepping into the world of metalworking often feels like entering a different dimension filled with sparks, blinding lights, and complex terminology. You might have a broken lawnmower deck or a dream of building a custom workbench, but the sheer variety of equipment available can be paralyzing. It is completely normal to feel overwhelmed when you first see the rows of machines at the local welding supply shop.
The good news is that mastering the basics of metal fusion is well within your reach if you take it one step at a time. Understanding what are the 7 types of welding will give you the clarity needed to choose the right tool for your specific project. Once you recognize how each process works, you can stop guessing and start building with confidence.
In this guide, we will break down the most common welding processes used today, from the beginner-friendly MIG setup to the specialized industrial techniques. We will look at the pros and cons of each, the materials they handle best, and which ones belong in your home workshop. Let’s dive into the core methods that keep our modern world held together.
The Fundamentals of Metal Fabrication
Before we explore the specific categories, it is important to understand what is actually happening during the welding process. At its simplest, welding is the use of high heat to melt and join two pieces of metal together, often with the addition of a filler material. Unlike soldering or brazing, welding actually fuses the base metals into one single piece.
Most modern welding relies on electricity to create an electric arc, which generates enough heat to melt steel, aluminum, or stainless steel instantly. This arc is incredibly hot, often reaching temperatures over 6,000 degrees Fahrenheit. Because molten metal reacts poorly with oxygen in the air, most processes use a shielding gas or a chemical flux to protect the weld puddle.
Choosing the right process depends on the thickness of your material, the type of metal you are using, and the environment where you are working. A process that works great in a clean garage might fail miserably in a windy field. By learning the nuances of each method, you can ensure your joints are strong, safe, and professional-looking.
what are the 7 types of welding
When people ask what are the 7 types of welding, they are usually looking for a breakdown of the most common industrial and DIY methods. While there are actually dozens of specialized sub-types, seven specific processes stand out as the pillars of the industry. These range from manual “stick” methods to highly automated submerged arc systems.
For the average DIYer or garage tinkerer, only three or four of these will be practical for home use. However, having a broad knowledge of all seven allows you to understand how everything from bridges to spaceships is constructed. Each type offers a unique balance of speed, precision, and portability that makes it suitable for different applications.
In the following sections, we will examine MIG, TIG, Stick, Flux-Cored, Gas, Plasma Arc, and Submerged Arc welding. We will look at how they function and why a professional might choose one over the other. This foundational knowledge is the first step in becoming a proficient metalworker in your own right.
1. MIG Welding (GMAW) – The DIY Favorite
Gas Metal Arc Welding (GMAW), commonly known as MIG welding, is often the first choice for homeowners and hobbyists. It uses a thin wire that is fed through a “gun” at a pre-set speed. When you pull the trigger, the wire creates an arc, melts into the joint, and a shielding gas flows out to protect the weld.
The primary reason MIG is so popular is its ease of use; it is often described as a “hot glue gun for metal.” Because the wire is fed automatically, you don’t have to worry about manually adding filler material with your other hand. This allows you to focus entirely on your torch angle and travel speed, making it very beginner-friendly.
MIG is excellent for thin to medium-thickness steels and can also weld aluminum if you have the right gas and a spool gun. It produces very little “spatter” and results in a clean weld that requires minimal cleanup. It is the go-to method for automotive repair, furniture building, and general home maintenance.
2. TIG Welding (GTAW) – Precision and Artistry
Gas Tungsten Arc Welding (GTAW), or TIG welding, is the gold standard for high-quality, aesthetic welds. In this process, the welder uses a non-consumable tungsten electrode to create the arc. They then manually dip a separate filler rod into the molten puddle with their other hand, while often controlling the heat with a foot pedal.
TIG offers the highest level of control and produces the cleanest results, often referred to as “stacking dimes” because of the beautiful ripple pattern. It is the preferred method for welding thin materials, exotic metals like titanium, and high-performance components like roll cages or bicycle frames. However, it has a steep learning curve compared to other methods.
Because it requires two hands and a foot to operate, TIG is much slower than MIG. It also requires a very clean workspace, as any oil or dirt on the metal will ruin the weld. If you are looking to create show-quality pieces or work with very thin aluminum, TIG is the skill you want to master.
3. Stick Welding (SMAW) – The Outdoor Workhorse
Shielded Metal Arc Welding (SMAW), or stick welding, is one of the oldest and most versatile processes. It uses a consumable electrode (the “stick”) coated in a chemical flux. As the stick melts, the flux creates a gas shield and a layer of slag that protects the cooling metal from the atmosphere.
The biggest advantage of stick welding is its portability and ruggedness. Since the shielding is built into the electrode, you don’t need a heavy gas tank, which makes it ideal for outdoor work or windy conditions. It is also much more forgiving on dirty or rusty metal than MIG or TIG, which is why it’s used for farm repairs and heavy construction.
The downside is that stick welding is messy. It produces a lot of sparks and leaves behind a layer of “slag” that you must chip off with a hammer once the weld cools. It is also difficult to use on very thin sheet metal, as the high heat tends to blow holes through the material. Still, for heavy-duty repairs, it is an essential skill.
4. Flux-Cored Arc Welding (FCAW) – Power Without the Tank
Flux-Cored Arc Welding (FCAW) is very similar to MIG welding in that it uses a wire-fed gun. However, the wire itself is hollow and filled with flux. This means you can weld without an external shielding gas tank, making the machine much more portable for a garage DIYer on a budget.
This process is fantastic for welding thick materials and can achieve deep penetration in a single pass. It is often used in structural steelwork and heavy equipment repair. Like stick welding, it handles wind well and can burn through some surface contaminants that would stop a MIG welder in its tracks.
The trade-off for this convenience is more smoke and spatter. Your finished welds will also be covered in slag that needs to be cleaned. Many entry-level “MIG” machines sold at big-box stores are actually flux-cored machines, so it is a very common starting point for people learning what are the 7 types of welding in a home shop.
5. Gas (Oxy-Fuel) Welding – The Old School Versatility
Oxy-fuel welding uses a torch that mixes oxygen and a fuel gas (usually acetylene) to create a high-temperature flame. Unlike the previous methods, this does not use electricity. The welder uses the flame to melt the base metal and manually adds a filler rod to the puddle, much like TIG welding.
While gas welding has mostly been replaced by arc welding in modern manufacturing, it remains a valuable skill for brazing, soldering, and cutting metal. An oxy-acetylene setup is like a Swiss Army knife for the workshop. You can use it to heat up stuck bolts, bend thick steel bars, or even cut through plate steel with a special attachment.
For actual welding, it is slower than arc methods and produces a larger “heat-affected zone,” which can warp thin metal. However, it is a very quiet and portable way to join metal without needing a high-amperage electrical outlet. Many vintage car restorers still use gas welding for delicate bodywork repairs.
6. Plasma Arc Welding (PAW) – High-Tech Precision
Plasma Arc Welding (PAW) is a more advanced cousin of TIG welding. It uses a specialized torch where the arc is constricted through a fine copper nozzle. This creates a very narrow, high-velocity jet of plasma that can reach incredible temperatures and provide extreme precision.
PAW is primarily used in high-end industrial applications where speed and accuracy are critical. It allows for deeper penetration than TIG and is less sensitive to the distance between the torch and the metal. You will often see this used in the aerospace industry or for manufacturing medical instruments where every millimeter counts.
For the average DIYer, Plasma Arc Welding is rarely used because the equipment is significantly more expensive and complex than a standard MIG or TIG setup. However, many hobbyists do use plasma cutters, which utilize the same basic technology to slice through metal like a hot knife through butter.
7. Submerged Arc Welding (SAW) – Industrial Heavyweight
Submerged Arc Welding (SAW) is a process you won’t find in a home garage, but it is vital to heavy industry. It involves a continuously fed wire electrode, but instead of gas, the weld is “submerged” under a thick layer of granular flux. This flux prevents sparks and fumes while allowing for incredibly high heat and deposition rates.
Because the arc is hidden under the flux, the welder doesn’t even need a helmet to watch the process (though safety gear is still required). SAW is almost always automated or semi-automated and is used to weld huge pressure vessels, ship hulls, and structural beams for skyscrapers. It produces extremely high-quality, deep-penetrating welds at high speeds.
Understanding SAW helps round out your knowledge of the industry. It represents the “heavy lifting” side of fabrication. While you won’t be using it to fix your lawn furniture, it is the reason why the massive steel structures we rely on every day remain standing and safe.
Safety Gear and Workshop Setup for Beginners
No matter which of the methods you choose, safety is the most important part of your workshop setup. Welding produces intense ultraviolet light that can cause “arc eye” (essentially a sunburn on your eyeballs) in seconds. You must invest in a high-quality auto-darkening helmet to protect your vision.
You also need to protect your skin from UV rays and hot sparks. This means wearing a heavy-duty leather welding jacket or apron, along with leather gloves. Never weld in synthetic fabrics like polyester, as they will melt to your skin if a spark hits them; stick to 100% cotton or leather.
Proper ventilation is the third pillar of safety. Welding creates fumes that can be toxic if inhaled over long periods. Always weld in a well-ventilated area, or use a fume extractor if you are working in a confined space. Keeping your workspace clean and free of flammable materials like sawdust or gasoline is also crucial for preventing fires.
Choosing the Right Welder for Your Home Shop
If you are just starting out, I usually recommend a multi-process welder. These machines are designed to handle MIG, Stick, and sometimes TIG all in one unit. They offer the best value for a DIYer because you can start with easy MIG projects and eventually try your hand at TIG or Stick without buying a new machine.
Consider your electrical situation before buying. Most professional machines require a 220V outlet (like a dryer plug), but many modern “inverter” welders can run on a standard 110V household outlet. While 110V machines are limited to thinner materials, they are perfect for most home repairs and light hobby work.
Think about what you will be welding most often. If you plan on doing a lot of outdoor gate repairs, a flux-cored or stick welder is best. If you want to build custom aluminum parts for a motorcycle, you will need a TIG welder with AC/DC capabilities. Matching the tool to the task will save you hundreds of dollars in the long run.
Frequently Asked Questions About what are the 7 types of welding
Which of the 7 types is the easiest for a beginner to learn?
MIG welding (GMAW) is widely considered the easiest for beginners. The automatic wire feed allows you to use one hand for the torch, making it much easier to control the weld puddle than TIG or Stick welding.
Can I use one machine for all 7 types of welding?
No, there is no single machine that can perform all seven types. However, multi-process welders can often handle MIG, Stick, and TIG. Specialized industrial processes like Submerged Arc or Plasma Arc require dedicated, expensive equipment.
What is the strongest type of weld?
Strength depends more on the skill of the welder and the proper penetration than the process itself. However, TIG and Submerged Arc welding are known for producing extremely high-quality, structurally sound joints when performed correctly.
Do I really need a gas tank for my home welder?
Not necessarily. If you use Stick welding or Flux-Cored welding, the shielding is provided by the electrode or the wire itself. This eliminates the need for a gas tank, making your setup more portable and affordable.
Is welding at home safe?
Yes, welding at home is safe as long as you follow strict safety protocols. This includes wearing proper PPE, ensuring excellent ventilation, and keeping a fire extinguisher nearby at all times. Always read your machine’s manual before starting.
Summary of Metal Joining Techniques
Learning what are the 7 types of welding is like learning the different tools in a carpenter’s belt. You wouldn’t use a sledgehammer to hang a picture frame, and you wouldn’t use a Submerged Arc welder to fix a thin exhaust pipe. Each process has a specific “sweet spot” where it performs best.
For most of us at The Jim BoSlice Workshop, MIG and Stick welding will be the bread and butter of our metalworking journey. They provide the best balance of affordability and utility for the projects we tackle in our garages. However, don’t be afraid to branch out into TIG if you want to elevate your craftsmanship to a professional level.
The most important thing is to just start practicing. Grab some scrap metal, put on your helmet, and start laying beads. With time and patience, you will develop the “muscle memory” needed to create strong, beautiful welds that will last a lifetime. Metalworking is a superpower—now go out there and use it!
