Welding is a family of processes, not one interchangeable technique. The process names describe how heat, pressure, shielding, and filler metal are used to create a joint. Choosing among them depends on the base material, thickness, joint design, welding position, work environment, required output, applicable procedure, and qualifications of the person doing the work.
This article was originally written by Jamie Levy for BriteArc Fabricators in February 2023 and was independently rewritten, fact-checked, and expanded in August 2026. It describes processes used across the welding industry; it is not a claim that BriteArc offers every process listed.
Eight welding processes you may encounter
1. Gas metal arc welding (GMAW)
GMAW feeds a continuous consumable wire through a welding gun while an external gas shields the arc and molten weld pool. It is often called MIG welding, although the exact shielding-gas terminology can be more specific. The continuous wire can support efficient shop production, but wind, surface condition, joint access, settings, and gas selection all affect results.
2. Gas tungsten arc welding (GTAW)
GTAW, commonly called TIG welding, creates the arc from a non-consumable tungsten electrode. Filler metal can be added separately when the joint requires it. The process gives the welder precise control and is widely associated with clean, detailed work, including suitable stainless steel and aluminum applications. It is generally less productive than continuous-wire processes where deposition rate is the main priority.
3. Shielded metal arc welding (SMAW)
SMAW, or stick welding, uses a short consumable electrode with a flux coating. The coating helps protect the weld as the electrode is consumed and leaves slag that must be removed. Relatively portable equipment and the absence of an external shielding-gas cylinder can make SMAW practical for many construction, maintenance, and field situations, subject to the electrode, material, procedure, and conditions.
4. Flux-cored arc welding (FCAW)
FCAW is a continuous-wire process that uses a tubular electrode containing flux. Some wires are self-shielded; others require external shielding gas. The wire classification and approved procedure determine how it is used. FCAW can provide useful deposition rates and field capability, but it should not be reduced to the claim that every flux-cored wire is automatically suitable outdoors.
5. Plasma arc welding (PAW)
PAW uses a constricted arc passing through a nozzle to create a concentrated heat source. It shares some characteristics with GTAW but uses a different torch arrangement and arc control. Plasma welding is generally associated with specialized, controlled applications rather than ordinary mobile repair work.
6. Resistance welding
Resistance welding generates heat through electrical resistance while components are held together under force. Spot, seam, and projection welding are examples. These processes are common in repeatable manufacturing applications and use equipment and joint arrangements that differ substantially from manual arc welding.
7. Metal-cored arc welding (MCAW)
MCAW uses a composite tubular wire whose core is mainly metallic powders and alloying ingredients. It is generally used with shielding gas and can support high deposition efficiency in suitable shop or production applications. Metal-cored wire is not the same as flux-cored wire, even though both electrodes have a tubular construction.
8. Submerged arc welding (SAW)
SAW forms the arc beneath a layer of granular flux. The covered arc and continuous electrode make the process well suited to mechanized, repeatable welds on suitable heavier work. Equipment arrangement and welding position make it a controlled production process, not a general answer for irregular site repairs.
How the process is actually selected
The familiar labels MIG, TIG, and stick are useful starting points, but they are not a specification. A welding procedure must account for the joint and service requirements. Relevant considerations include:
- Base-metal type, grade, thickness, and condition
- Joint geometry, fit-up, access, and welding position
- Required mechanical properties and quality level
- Applicable code, drawing, procedure, or repair direction
- Shop, outdoor, confined, elevated, or active-site conditions
- Preheat, interpass, filler-metal, shielding, and inspection requirements
- Welder qualifications and available equipment
- Production volume, deposition needs, and finish expectations
A process that is efficient on clean assemblies in a shop may be unsuitable beside wind, moisture, coatings, poor access, or combustible materials. Likewise, a portable field process may not provide the control or productivity needed for a repeatable shop assembly.
Process choice does not replace safety planning
All welding processes bring hazards that must be assessed and controlled. Arc radiation, heat, electricity, fumes, gases, noise, compressed cylinders, fire, and explosion risks vary with the process, consumables, coating, material, and work area. The Canadian Centre for Occupational Health and Safety recommends hazard assessment, appropriate controls, ventilation, safe work practices, training, and personal protective equipment based on the actual exposure.
What to ask a fabricator or repair welder
Instead of requesting a process by nickname, describe the material, component, failure or desired result, location, access, and applicable drawings. A qualified fabricator can then explain which process and preparation fit the work. For shop and field scopes that match BriteArc’s capabilities, review mobile welding, structural steel, and stainless and aluminum fabrication, or send the project information for review.
