Which welding process is best? That depends on the application.
The following is a short
description of each: Arc (Stick) Welding or SMAW (Shielded Metal Arc Welding): Arc welding is one of the oldest welding processes around. It can be the cheapest to start with as there is not a lot of equipment needed. It is also very versatile as there a lot of specialized electrodes available. ome of the main features and limitations are: Ine!pensive "as specialized electrodes for hardening# high$strength# stainless# mi!ed# cast iron and other metal alloys %ses a flu! coating to shield weld. Weld will need to have flu! cleaned off &ery difficult on thin metal Ta'es considerable training and practice to master. (ortable as no need to carry gas or wire feeder. Wor's on A) or *) Arc welding is nice for its simplicity in the equipment. It ta'es practice to do consistent and proper welds. There are dozens of types of rods +electrodes, available. ome of the most common are: -.// $ *eep penetration# cellulose -./0 $ 1eneral purpose# easy to use. 2./3 $ 4ow (enatration# great for thin metal 2./5 $ 4ow$hydrogen# higher strength. 6ods need to be 'ept dry# usually in an oven. They are also more productive as far as amount of weld per minute. 7ic'el8ilicon $ *esigned for )ast Iron. Two main types depending on 7ic'el content. "igh nic'el content is stronger but very hard and cant be machined. 4ower nic'el content for machinability. tainless $0.5# 0.9 and 0/- grades available. :ost *I; welders will use -./0 rods as they are widely available and relatively easy to use. 7ote# the quality of the rods ma'e a big difference on their ease of use. <lectrodes can be purcased in differnt sizes from /8/-= to /83=. >or *I; use /85= or less will be used. I find ?8-3= or 080@= rods are the most useful. 7ote: thin metal is difficult with arc welding. I found some /8/-= +/.-mm, 2./3 rods that wor' well on ...3. steel. MIG Welding :I1 welding +:etal# Inert 1as, welding is also call 1:AW +1as# :etal Arc Welding., It uses a thin wire as an electrode and filler fed by a wire feeder to the gun. The power source is constant voltage +)&, *). There are two main process 1as +:I1, and gasless +flu! core., Aelow is a comparison of the two: Gasless MIG (FCAW - Flux Core Arc Welding): *oes not need shielding gas# saves cost of bottles# regulator. Wire is more e!pensive. It is more portable# no gas to transport. %ses flu! core to shield weld. )auses slag and spatter that must be cleaned up. (roduces smo'e that ma'es it hard to see weld. "as deeper penetration than gas :I1. <asier on positional welds +overhead and vertical., *irect$)urrent# <lectrode 7egative (olarity +*)<7, mallest wire available is ...0.= +..5mm,B not easy to use on thin metal. Gas MIG (GMAW): &ery clean welds with no slag or spatter. %ses Argon8)C@ or straight )C@ as a shielding gas. Wire is less e!pensive. :ore comple! than >lu! )ore 4ess portable *irect$)urrent# <lectrode (ositive polarity +*)<(, Wire size down to ...@0: +..-mm,# great for thin metal. The wire is fed via from a roll wire feeder to the gun. :I1 is the easiest process to learn# but requires gas and a wire feeder so it is not as portable. :I1 is great for thin metal especially auto body wor'. TIG Welding, GTAW (Gas Tungsten Arc Welding): TI1 welding is also very versitile and produces the highest quality welds. It also ta'es considerable practice and is least productive. TI1 uses an torch with a tungsten electrode. Argon is used as a shielding gas to protect weld and tungsten. An arc is struc' between the tungsten and the wor' and a short gap is maintained. As the weld progresses# filler wire is dipped in the weld pool. (ower source is constant$current *) or A) depending on metal used. )ontrolling the torch# feeding wire# moving at the right speed and also using the correct current ma'es it physically more complicated. %sing a footpedal# you have / foot and both hands busy. It is easier for bench wor' +I use a barstool ., TI1 can do Dust about any metal with A) and a *) power source. *) is used on ferrous metals +steels., A) is used on aluinum. This *I; welder only does *). So, Which o I !se" As usual# that depends B, >or building a *I; welder# arc welding is cheapest and simplest. It is a versitile starting point. 1reat for farm repairs as it is the most portable. *ifficult on thin metal. If you plan on doing bodywor'# then gas :I1 is best. That will require adding a wire feeder# gun# gas bottle and regulator to the basic arc setup. I prefer :I1 for its clean welds. "owever# if I need to lug the welder out somewhere for a quic' fi!# I use stic'. If you are building something li'e a off$road buggy frame# then TI1 is preferred as you have the most control over the welds. I use arc 5.E of the time. TI1 for aluminum and :I1 for thin metal.