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Welding is a process used in metal fabrication, construction, manufacturing, and much more.
From repairing machinery to constructing vehicles, welding plays a crucial role in multiple UK industries. In this guide, we’ll cover what welding is, how it works, common processes and joints, and what it’s used for.
Whether you’re an apprentice or just want to find out more, our guide is a great place to start.
Welding is the process of joining materials - usually metals - using heat, pressure, or both. There are various types of welding, such as MIG/MAG, TIG or stick, each with its own advantages and ideal uses.
If you’re a welder, you can use these techniques for a wide range of fabrication or repair tasks.
Welding fuses two or more materials to form a strong joint. The materials being joined are known as the parent materials. Sometimes, a filler metal or consumable is used to strengthen the bond.
Welds can be classified into:
Fusion welding (like MIG, TIG or stick welding) uses heat to melt the parent and filler materials together.Pressure welding joins materials through friction or force, sometimes with heat applied alongside.
The welding process produces a molten material, known as the weld pool, which solidifies to create a bond. In some welds, shielding gas is used to protect the bond from defects or contaminants in the environment.
Here are some of the most common welding techniques, each suited to different materials or situations.
In this guide, we’ll focus on arc welding. MIG/MAG, TIG and stick welding are all subtypes of arc welding.
Arc welding is a common welding process that uses an electric arc to create heat, which melts the parent materials and filler metal to form a strong bond. It can be used to join a wide variety of metals together.
This type of welding is often used for heavy-duty construction, as the high heat can warp thin materials.
MIG welding uses a continuous feed of wire electrode that melts as the electric arc heats the base materials.
It stands for Metal Inert Gas Welding and is one of two subtypes of Gas Metal Arc Welding (GMAW). The other is Metal Active Gas (MAG), which uses active gases like helium rather than inert gases like argon.
In both types, the process works with a welding torch, or ‘gun’. When the torch trigger is pressed:
The process uses shielding gas (inert for MIG, active for MAG) to protect the weld from contamination.
Because of its speed, versatility, and ease of automation, MIG/MAG welding is one of the most widely used welding processes in industrial settings. However, it can be tricky to do outside as gas can blow away.
Common uses include:
You can find out more about MIG welding here, in our beginner’s guide to the technique and its uses.
Although sharing some similarities, there are some key differences between TIG and MIG/MAG welding.
TIG (Tungsten Inert Gas) welding uses a tungsten electrode to generate an arc that melts the base metal, creating a molten weld pool. Unlike MIG/MAG welding, the tungsten electrode does not melt.
Instead, a separate filler rod is manually fed into the pool if needed. Shielding gas is used to protect the weld.
TIG welding is a slower welding process than MIG, but results in a stronger and better-looking weld when it’s completed by a skilled welder. You have to carefully manipulate the weld pool and feed in the filler wire.
TIG welding can be done from a variety of positions, where precision and quality is more important than speed. It’s especially useful for aerospace, food equipment, high-purity processing, and motorsports.
You can find out more about TIG welding here, in our one-stop guide to this type of welding process.
Stick welding is also known as Manual Metal Arc or MMA welding. It is one of the oldest types of welding.
Instead of shielding gas, stick welding uses a consumable electrode coated in flux to create an arc and weld the metal. During stick welding, the flux coating burns off the electrode, creating a protective slag layer.
After the molten weld pool has cooled, the slag layer must be chipped away to expose the clean weld.
Unlike MIG/MAG and TIG welding, stick welding doesn’t need bottled gas. This makes it a good welding process for harsh or outdoor environments. It works well for thick materials that don’t have to look perfect.
Keep in mind that stick welding requires additional time for chipping away the slag layer. While not as precise as TIG welding, or as fast as MIG welding, stick welding is affordable, portable, and ideal for dirty metals.
Want to know more about how stick welding works? Check out our guide to stick welding basics.
MIG/MAG, TIG and stick are types of welding our industry-leading welding equipment can help you with. However, there are many other types of arc welding (and other welding processes), including the below:
Now we’ve explained welding’s definition and some common processes, let’s look at how weld joints work.
A key part of welding is choosing how to join materials together. Joints affect the strength, appearance, and durability of the weld. Here are five common types of joints, how they work, and what they’re used for.
Weld Joint
How it Works
Common Uses
Butt
Two workpieces are placed in the same plane and the side of each workpiece is joined by welding along their edges
Pipelines and structures
Lap
The surfaces of the two workpieces overlap each other, and the weld is formed where the two surfaces intersect
Sheet metals, joining different thickness
Edge
Workpieces are aligned parallel to each other and welded along their edges (not suitable for load-bearing welds)
Where workpieces are not subject to stress
Tee
One workpiece is welded perpendicular to another, forming a T-shape, offering high mechanical strength and durability
Structural steel, machinery, supports
Corner
Two workpieces form a 90° angle and are welded at the corner (easy to assemble and requires little preparation)
Box frames, cabinets, metal furniture
Read our dedicated blog post about basic types of weld joints and useful tips for getting a high-quality result. As well as these popular joints, different weld types can be used to create strong, lasting connections.
For example, groove welds are made in a prepared groove between two pieces, often used for full penetration in structural welding, pipelines or pressure vessels. Fillet welds, which form a triangular shape, are common in Tee and corner joints, providing cost-effective strength with less filler material than butt.
Others include plug welds, which fill circular holes to fuse overlapping materials, and slot welds, which use elongated holes to distribute stress evenly. These may replace rivets in auto and structural applications.
Choosing the right welding process for the job is important, but what are some practical applications?
Welding plays a crucial role in multiple UK industries, from building vehicles to green energy equipment.
In the manufacture, repair and maintenance of vehicles and machinery, strength and speed are essential.
Welding plays a significant role in construction, including in buildings, bridges, and pipelines. In construction, weld joints need to be designed to handle heavy loads and withstand extreme weather conditions.
Welding is often used for repairs and maintenance, for example fixing a broken part or worn-down machinery.
Specialised fields like aerospace also use welding, requiring the highest quality welds on unusual materials.
In submarine construction, stick and submerged arc welding are used for strong, durable welds on thick materials that must withstand high pressure. Hobbyists, craftspeople, and sculptors also use welding.
Our guide should have given you an overview of what welding is and how different welding processes work.
If you want to become a pro welder, or just do some weekend metalwork, start your journey with ESAB.
No matter the project, we offer a wide range of welding equipment, welding accessories, and PPE for your needs. Our portfolio of high-performance yet user-friendly MIG welders, TIG welders and stick welders offer:
Or, browse our ESAB University section for the latest welding articles, expert videos, and courses.