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1. Arc Welding (AW)

• General: Uses an electric arc to melt base metals and electrode to form a weld pool that solidifies.

Shielded Metal Arc Welding (SMAW) / Stick Welding

• Uses a consumable electrode coated with flux.

• Filler metal matches base metal.

• Common for steels; not ideal for aluminum, copper, titanium.

• Disadvantages: Frequent rod replacement, flux may melt prematurely at high currents.

Gas Metal Arc Welding (GMAW) / MIG

• Uses bare wire electrode with shielding gas.

• Advantages: Continuous wire = higher deposition rate, no slag, automatable.

Flux-Cored Arc Welding (FCAW)

• Like SMAW but electrode is a tubular wire filled with flux.

• Offers higher efficiency and is better suited for automation.

Electrogas Welding

• Vertical position welding with flux-cored or bare wire, shielding gas, and molding shoes.

Submerged Arc Welding (SAW)

• Uses bare wire and granular flux to shield arc.

Gas Tungsten Arc Welding (GTAW) / TIG

• Uses non-consumable tungsten electrode and inert gas.

• Advantages: High-quality welds, no spatter/flux.

• Disadvantages: Slower, costlier.

Plasma Arc Welding (PAW)

• Modified GTAW with plasma jet.

• Advantages: Excellent weld quality, deep penetration.

• Disadvantages: Expensive, bulky torch.

2. Resistance Welding (RW)

• Combines heat (from electrical resistance) and pressure.

• No filler metal, high production potential.

• Limited to lap joints, high equipment cost.

Types:

• Spot Welding: Welds localized spots via electrodes.

• Seam Welding: Rotating wheel electrodes make continuous welds.

• Projection Welding: Welds formed at raised projections on parts.

3. Oxyfuel Gas Welding (OFW)

• Burns fuel gas with oxygen.

• Main type: Oxyacetylene Welding (OAW).

• Produces a high-temp flame; inner cone is hottest.

4. Electron Beam Welding (EBW)

• Uses a focused electron beam in vacuum to melt metals.

• Advantages: Deep, narrow welds, minimal distortion.

• Disadvantages: Expensive, needs vacuum, generates X-rays.

5. Laser Beam Welding (LBW)

• Coalescence via a focused laser beam.

• Suited for precision work and automation.

6. Solid-State Welding (SSW)

• Coalescence via pressure and/or heat (below melting point).

• No filler metal.

Types:

• Forge Welding: Heat and hammering.

• Cold Welding: Pressure at room temperature.

• Roll Welding: Pressure through rollers.

• Diffusion Welding: Heat, pressure, and time under vacuum or controlled atmosphere.