A Quick comparison of Welding Processes

SMAW: Shielded Metal Arc Welding AKA: Stick, Arc, Rod Burning, Stinger

GTAW: Gas Tungsten Arc Welding AKA: TIG, Heli-Arc

GMAW: Gas Metal Arc Welding AKA: MIG, wire-feed welding, wire welding

OFW: Oxy-Fuel Welding AKA: torch welding, gas welding

OAW: Oxy-Acetylene Welding AKA: OFW (OAW is an older term)

FCAW: Flux Core Arc Welding AKA: wire welding, cored wire

(note: the acronyms are American Welding Society (AWS) standard designations)

Descriptions

SMAW: Electrode is heat source and filler metal. Smoke and slag protect the molten weld. Typically, the electrode is a coated rod of steel only 16 inches long - this is burnt down and a new one replaced in electrode holder. Each one lasts only a minute (more or less). Slag must be chipped from the weld after it is made.

GTAW: Electrode is the heat source but is not melted. Filler rod is added to molten weld. A shield gas is added to the weld zone by the torch. Precise, clean welds. Excellent for stainless steel, aluminum, bronze, tool steel. It is time-consuming.

GMAW: Electrode is the heat source and filler metal. A protective shielding gas is added to the molten weld zone by the torch. The electrode is fed from a continuous spool of wire. I refer to it as similar to a hot glue gun: just pull the trigger and go. Great for fabricating steel sculptures. Major disadvantage is that it is easy to make a great looking weld that has virtually no strength, unless you set the machine correctly.

OFW: A flame from a hand-held torch is the heat source. Filler metal can be added to the molten weld pool. Time consuming, but a new welder can easily see how the base metal is melting, filler rod added and melting. A great way to learn how to read the puddle and learn how to manipulate the molten weld pool against forces of gravity. Technique is similar to the one used for TIG. Easy to work directly and intuitively. Equipment is inexpensive.

FCAW: Quite similar to GMAW (wire feed welding). The main difference is that the wire is hollow core and filled with material similar to SMAW electrode coating. Some of the electrodes are meant to create all of the shielding gas (smoke, really) or work along with an added shield gas. Not quite so clean as GMAW, but you can do it with no additional cylinder of gas. Great for thick metal. Many applications which only used stick welding are now going to FCAW.

Valerie Weihman-Rock 2004