Different types of welding: MIG vs TIG vs Arc & more.

To get a better understanding of the different types of welding, it’s good to know what it is and what goes on behind the process. Welding is the fabrication process parts are melted or fused together with heat and pressure. It depends on what materials you use as well; it could be wood, thermoplastics, or metal. This process simply binds smaller parts together in order to produce more complex structures. The level of experience and the different applications determine what welding type would be the best fit for the job. 

How Does Welding Work 

When it comes to the actual welding process, parts are fused by melting the filler (involves sending an electrode to the weld point) material at the joining point. There are three main techniques that help achieve this: Gas welding, Arc welding, or Laser welding. 

 

Parent Materials used in welding 

When welding is carried out, various materials are used to create various joints. Each of those materials requires different methods of welding. These materials can range from wood and metals to thermoplastics. However, the difference between these materials comes down to the temperature.  

If you’re going to use the metal welding process, it involves metal parent material. This material is heated up and combined with other materials to produce a strong weld joint. 

When the material has finally melted down, it becomes substantially stronger than the parent material itself. To prevent contamination or oxidation, a shielding gas is typically used to protect the weld fillers. 

 

When you’re working with plastic materials, this usually happens in three stages and the heating stages can be defined as internal and external. 

1. The surface area is prepared and pressure is used to bring it together.

2. Heat is applied through short and controlled bursts. 

3. While it’s in the cooling phase, pressure is applied to the materials.

 

If you’re looking for something more robust and quicker without dealing with abrasives or nails, the wooden parent material is a good choice. What really happens when heat is applied to the material is that it undergoes an intense amount of pressure while being heated through direct motion. This is what creates heat on the surface which bonds pieces together. 

 

Types Of Welding 

The four standard processes of metal welding are MIG, TIG, ARC, and STICK. The point here is that not every process is a  “one fits all” solution or in this case, application. Each welding process will require different applications and it’s important to understand what they are. 

 

MIG Welding 

Metal Inert Gas (MIG) is a relatively simple process. The only worry that you would have to keep in mind is choosing the right shielding gas and setting the welder’s parameter. 

With the different variations of welding, you can decide on whether you want a thin or thick layer of metal for your parts. What you need to keep in mind is that your welding process depends on the output of power. If you have a wider range of power, the best chance you have to regulate the amount so that you’re able to work on various types of metal without the risk of burn-through. For stronger and resistant pieces, the higher the power output,  the better. 

Benefits 

• Lowers heat input to work area. 

• Suitable for beginners as it’s easy to use.

Disadvantages 

• Must have a shielding gas for the electrode.

• Higher cost and require additional equipment.

• The positions and direction for welding are limited.

• Cleaning must be done regularly for rust and dirt.

 

TIG welding 

Tungsten Arc Welding (TIG) is said to be more sophisticated in comparison to MIG welding. This process is known to use a non-consumable tungsten electrode to heat and melt the base parent metal. Keep in mind that Tungsten has a very high melting point, so the electrode will not dissolve under high temperatures while creating the joints. 

Unlike MIG welding, it removes the need for material fillers. The type of filler you use really comes down to what project you’re working on and whether you need an electrode arc or not. The only thing to keep in mind is that with TIG welding, you won’t have to replace the electrode as feeding is not involved. The only thing that needs to really be done is to fill the gas tank for overall maintenance.

Benefits

• No splatter or waste.

• Creates precise and clean welds. 

• Works with very thin welds.

• Produces a pleasing finish.

• Helps you control heat input. 

Disadvantages 

• Equipment is expensive. 

• Requires external shielding gas which can be difficult and expensive to manage. 

• This requires a higher learning curve in comparison to MIG.

• May require additional metal deposits

 

ARC Welding 

flux-core welding (ARC) is pretty similar to MIG. In terms of those similarities, both processes require feeding via a consumable electrode to form a welding arc. What makes the one unique from the other is that Arc welding uses the flux core to produce dual-shielding gas, 

MIG requires an external gas source. Keep in mind that with every consumable electrode within a system, you will have to change it every time and again. This is a great place to use thicker and heavier materials because Arc welding does generate a lot of heat. 

Benefits 

• Equipment is cost-effective.

• Easy to transport. 

• Out-position welding is effective 

• Works well with porous metal.

Disadvantages

• Risky for thinner materials. 

• More waste is produced.

• Require highly skilled workers.

 

STICK Welding 

STICK welding, also known as shielded arc welding, is a super popular method for home and workshop projects. It involves delivering the electrode to the melting point where joints are fused together. 

The process involves a flux core and consumable electrode. This creates the welding arc between the electrode and working materials. When you’re heating up the electrode, over time you will need to replace it during the welding process. What’s good about this welding process is that it offers protection against contaminants using the flux coating that disintegrates around the weld area. 

If you’re looking to create structures that are heavy and thick in metal, this process is key. Stick welding is able to work with heavier and thicker metals, making it ideal for any projects that need to withstand unfavourable environments. Whether you’re a DIY hobbyist or a work-from-home handyman, it truly changes the way you work. 

Benefits 

• Works best with thick materials. 

• Creates strong welds. 

• Suitable for indoors and outdoors.

• No need for shielding gas.

• Ideal for heavy-duty construction. 

• Works well with rust and dirty metals 

Disadvantages 

• Not compatible with thin metals.

• Clean up required to clear flux disintegration. 

• Impairs productivity due to replacing electrodes frequently.

• Splatter and slag 

• Time-consuming and requires skilled workers

 

Overview

In general, welding has always been a highly sought-after skill in automotive, construction, and industrial companies. Whether you love working with your hands or work for an in-demand, highly paid career, the results you’re hoping for could very well be worth the long-term investment. If you’re hoping to become more resilient and efficient, take the time to scan over what welding type your projects need. 

Yaskawa Robotic Solutions is more than happy to help you decide on the best welding type and the best robotic models, contact us for more information.