22 Different Types of Metal Welding (And Their Applications)

You might have a question “How many welding types are there?”
Well, there are more than 20+ types of metal welding processes.

Here, I have mentioned the different types of welding and their applications.

So let’s dive right into it.

Different types of welding

Different types of metal welding are mentioned below.

(Note: For detailed information on each of these welding processes, just click on the above links to visit the separate articles.)

So if you have seen the different types of welding, then let’s see their applications.

Types of welding and their applications

#1) Applications of Oxy-acetylene gas welding

  • Oxy-acetylene gas welding is used for welding of copper, carbon steel, aluminum, bronze.
  • Welding of sheet metals and small diameter pipes can be effectively done by using the Oxy-acetylene gas welding process.
  • The metal plates having thickness upto 8mm – 10 mm can be welded easily by using this process.
  • Red brass and yellow brass welded using Oxy-acetylene gas welding to minimize the vaporization of zinc.

#2) Applications of Shielded Metal Arc Welding (SMAW)

  • Shielded Metal Arc Welding (SMAW) process is used for almost all the engineering materials.
  • By using this process, it is difficult to weld the metals which have low melting point and are highly reactive.
  • Metal plates having thickness upto 25 mm can be welded using SMAW welding process.
  • Using shielded metal arc welding, the welding can be done in vertical and overhead positions too.
  • Shielded metal arc welding is used in structural works like storage tanks, bridges, etc.
  • For welding of heavy metal pieces, usually grooves are made at the weld surface.

#3) Applications of Submerged Arc Welding

  • Submerged arc welding is used for welding of copper alloys, carbon and alloy steels.
  • Submerged arc welding process is generally applicable for welding the plates having thickness more than 10 mm.
  • This process is highly suitable for automatic welding in boilers, pressure vessels, ship building, etc where high quality welding is required for larger plates.
  • Submerged arc welding is only suitable for flat horizontal surfaces and it is not applicable for welding of cast iron.
  • Plates having thickness up to 300 mm to 400 mm can also be welded by making “U-groove” between them.
  • Automatic submerged arc welding process is suitable for welding of pressure vessel cylinders and pipes with higher thickness.

#4) Applications of TIG welding and MIG welding

  • Using TIG welding and MIG welding, all the engineering metals can be welded except zinc.
  • The plate thickness from 1 mm to 6 mm can be welded using TIG and MIG Welding.
  • TIG welding process is applicable to all the non ferrous metals as well as alloy steel.
  • MIG welding process can be semi automatic or fully automatic and it can be used for welding of non ferrous metals as well as stainless steel pressure vessel parts.
  • Automated orbital TIG welding process with cold wire feed is used for welding a large number of tubes in a boiler.
  • By using TIG welding process, the titanium alloy tubes with wall thickness 1.6 mm and below can be welded without using any filler material. But if the thickness of tubes is more, then the filler material is used.

#5) Applications of Plasma Arc Welding

  • Plasma arc welding is suitable for welding of reactive metals.
  • The equipment used for the plasma arc welding process are costly and can be used for welding of flat and horizontal surfaces.
  • The plasma welding is used for welding of nickel alloys as well as refractory metals.
  • This process is also used for coating of refractory metal on the metals.

#6) Applications of Spot Welding, Projection Welding and Seam Welding

  • Spot welding, projection welding and seam welding are the types of resistance welding, which are widely applicable in sheet metal welding of automobile parts, tube manufacturing, as well as many other sheet metal welding operations in industries.
  • If you want to use any of the resistance welding process, then precautions must be taken for welding of highly conductive materials like copper and aluminum.
  • Flash welding or induction welding is generally used for welding of tubular joints in boiler construction.
  • Radiators used in automobile industries are either brazed or resistance seam welded.
  • Seam welding process is usually applicable for welding of sheets having thickness less than 5 mm.

#7) Applications of Electroslag Welding

  • Electroslag welding is suitable for welding thick sections of alloy steel (50 mm or more).
  • Electroslag welding is used for welding works in pressure vessels, steel plants, joining of large shafts, etc.

#8) Applications of Electron Beam Welding and Laser Beam Welding

  • Electron beam welding and laser beam welding are the types of radiant energy welding process which are used for welding of stainless steel, nickel alloys, titanium, zirconium and other reactive metals.
  • This process is also used for special applications in electronics industries as well as aerospace industries.
  • Laser welding is used in microelectronics circuits as it is suitable to make tiny spot welds.

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