The different welding processes: From MIG/MAG to TIG and more.

SMAW, better known as Shielded Metal Arc Welding (or colloquially ‘stick electrode welding’), is one of the oldest and most versatile welding processes. It uses a metal core wire covered with a flux. When the electrode melts, the flux creates a protective gas cloud and a slag layer over the molten pool. This protection prevents oxygen and nitrogen from the ambient air from coming into contact with the molten metal, which would weaken the mechanical properties of the weld.

✅ Relatively inexpensive, flexible in use (also outdoors), suitable for various materials and positions. 

❌Produces slag that needs to be removed, lower welding speed, requires a certain degree of skill.

Learn more about arc welding with stick electrodes (SMAW):

1. Superior Welding Performance Without Compromise: The New E 7018-1
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2. Classic Craftsmanship, Enduring Power: Coated Stick Electrodes, A Timeless Choice in Modern Welding.
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3. Rutile, basic or cellulose coated stick electrodes?
   Door Roel Litjens

GMAW (Gas Metal Arc Welding), commonly known as MIG/MAG welding (which stands for Metal Inert Gas/Metal Active Gas), is a widely used and productive welding process. It uses a continuously fed solid welding wire that serves as filler material. An external shielding gas protects the welding arc and the molten pool. MIG uses an inert gas (e.g., argon, helium, or a mixture thereof) and is suitable for non-ferrous metals such as aluminum, nickel, and copper alloys. MAG uses an active gas (e.g., a mixture of argon and CO2 or pure CO2) and is suitable for welding steel and stainless steel.

✅ High welding speed, relatively easy to learn, no slag formation, making it very suitable for automation.

❌Sensitive to wind (shielding gas is blown away), less suitable for outdoor use without additional protection.

Learn more about MIG/MAG welding (GMAW):

1. The Ultimate Solution for MAG Orbital Welding (Pipe welding)
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2. Stainless steel wires, Matt finish versus bright finish
   Door Mark van Haren
    
3. CEWELD Ultra Clean III : The best copper free welding wire!
   Door Peter Gerritsen

FCAW - MCAW, or flux-cored arc welding - Metal Cored Arc Welding, is closely related to GMAW and is often seen as a variant of it. It is a semi-automatic process that also uses an automatic wire feed, but with a hollow wire filled with deoxidizer (flux or powder) and/or alloying elements. This rutile or basic flux produces a protective slag and/or gas to protect the weld, similar to SMAW. There are two variants: self-shielded (no external gas required and commonly known as gasless wire) and gas-shielded (external gas required, despite the added flux).

✅ Higher welding speed than SMAW, deeper penetration, can often be used outdoors, less preparation of the workpiece required. 

❌Produces slag (even with external gas), more smoke than GMAW, more expensive wire than solid wire

Learn more about flux-cored arc welding (FCAW or MCAW):

1. The Truth About Deposition Rates: CEWELD Ultra Clean III (Uncoppered Wire) vs Metal cored (MCAW).
   Door Peter Gerritsen
    
2. The best welding wire; Rutile flux cored, Metal Cored or Solid welding wire?
   Door Roel Litjens
    
3. How to reduce Welding Fumes with more than 65%
   Door Mark van Haren

GTAW, better known as TIG welding (Tungsten Inert Gas), is a highly precise welding process known for its high-quality and aesthetic welds. It uses a non-consumable tungsten electrode to create an arc, and an inert gas (usually pure argon) protects the molten pool and tungsten electrode from atmospheric contamination. A separate filler wire (welding rod) is usually used.

✅ Very clean welds, precise control over the molten pool, suitable for thin materials and exotic metals (such as stainless steel, titanium, zirconium, nickel alloys, and aluminum)

❌Slower process, requires a lot of skill (eye-hand coordination), higher costs due to gas and special equipment.

Learn more about TIG welding (GTAW):

1. Can you weld Magnesium?
   Door Mark van Haren

SAW, or submerged arc welding, is an automated welding process that is mainly used for long, straight welds on thicker workpieces. The molten pool is completely covered by a layer of granular flux powder. This powder protects the arc and the molten pool from the ingress of nitrogen and oxygen from the ambient air and stabilizes the arc. The powder melts between 1000°C and 1350°C and forms a slag that protects the weld and slows down the cooling rate.

✅ Very high welding speed, deep penetration, high-quality welds, no spatter, good mechanical properties.

❌Limited to horizontal positions, not suitable for thin materials, requires large installation.

Learn more about submerged arc welding (SAW):

1. 66% Laskosten Besparen? 9,6 kg Neersmelt per Uur!
   Door Peter Gerritsen

ESAW, or electroslag welding, is a unique welding process used for welding/cladding various base materials to ultimately add a specific property to the material surface. This can be to improve corrosion resistance, but also to increase temperature resistance or improve resistance to cavitation or wear. The ESAW process is similar to submerged arc welding, but the flux (welding powder) has a lower electrical resistance so that the electric arc does not occur between the wire or strip and the workpiece, but the current passes through the welding powder. In the ESAW process, the welding voltage is between 24 and 26 volts, while in SAW welding it is usually between 28 and 34 volts.

ESAW, or electroslag welding, can be applied using either wire or strip. Typically, strip is used for surfacing and wire for joint welding.

✅ Very low dillution, very high melt rate.  

❌Highly specialized, requires specific experience, heavy power sources, and manipulation equipment.

Although often mentioned in the same breath as welding, soldering is a joining technique that works fundamentally differently. In soldering, materials are joined by melting a filler material (solder) that has a lower melting point than the materials to be joined. The base materials themselves do not melt. Capillary action draws the molten solder into the gap between the parts, where it solidifies and forms a joint.

✅Less heat input (sometimes less distortion), suitable for joining dissimilar metals, easier to learn.

❌Lower strength than welding, limited applicability for structural applications that must withstand high loads.