Welding Processes — Complete Guide to Every Welding Method

Every welding process exists because no single method works optimally for all metals, thicknesses, positions, and environments. Choosing the right process is the first decision that determines weld quality, speed, cost, and required skill level.

This section covers every major welding and cutting process, from MIG, TIG, and stick to specialized methods like submerged arc, laser, and resistance welding. Each guide includes parameter settings, technique breakdowns, material compatibility, and equipment requirements so you can set up and start welding with confidence.

Which Welding Process Should You Use?

The answer depends on four variables: what metal, how thick, what position, and where (shop vs. field).

• MIG (GMAW) — Fastest for mild steel and aluminum in a shop. Best for production, auto body, and general fabrication. Runs on 120V or 240V power.
• TIG (GTAW) — Highest quality and control. Required for thin materials, exotic metals, and X-ray quality code work. Slowest but produces the cleanest welds.
• Stick (SMAW) — Most portable, tolerant of dirty and windy conditions. Dominant in field, pipeline, structural, and maintenance welding.
• Flux-Cored (FCAW) — High deposition for structural and heavy fabrication. Self-shielded variant works outdoors without a gas bottle.
• Plasma Cutting — Fastest cutting method for steel, stainless, and aluminum under 1" thick. Cleaner cuts than oxy-fuel with less heat distortion.
• Oxy-Fuel — Cutting and heating thick steel. Standard for demolition, scrap, and heat bending. No electricity required.

Specialized Processes

These processes serve specific industrial applications. They’re less common in small shops but critical in manufacturing, automotive production, and heavy industry.

• Brazing & Soldering — Joins metals below their melting point using filler metal and capillary action. Standard for HVAC copper, carbide tooling, and dissimilar metal joints.
• Laser Welding — Extremely narrow heat-affected zone and high travel speeds. Used in automotive, medical device, and electronics manufacturing.
• Resistance Welding — Spot and seam welding for sheet metal. Every car body on the road has thousands of resistance welds holding it together.
• Submerged Arc (SAW) — Highest deposition rates of any process. Used for pressure vessels, structural beams, pipe, and shipbuilding where long, heavy welds are the norm.

How to Use This Section

Select a process above for complete settings charts, technique guides, and troubleshooting. If you’re not sure which process fits your project, start with the comparison above or check our process selection guide for a detailed walkthrough based on your specific materials and joint types.