Arc Welding
After years in the welding industry, we've seen how arc welding consistently delivers strength, precision, and versatility across a wide range of projects. It's a process that uses an electric arc to fuse metals, creating durable bonds that hold up under demanding conditions.
In this article, we explain what arc welding is, how it works, and where it's used. We also break down the most common types, from stick to TIG, and the essential tools and equipment needed for each method. Understanding these fundamentals is the key to achieving reliable results, whether the goal is structural fabrication, equipment repair, or detailed metalwork.
What this article covers:
What Is Arc Welding?
Arc welding is a process used to join metals by producing heat from an electric arc. The temperature generated is high enough to melt the base materials, allowing them to fuse together as they cool and solidify.
A power source creates the arc between an electrode and the workpieces, using either direct current (DC) or alternating current (AC), depending on the material and application. The result is a strong, permanent joint capable of withstanding mechanical stress.
How Does Arc Welding Work?
Arc welding works by establishing an electrical circuit between an electrode and the base metal. When the electrode is brought close to the metal surface, the electrical energy jumps the gap and forms an arc. This arc reaches temperatures of approximately 6,500 °F, melting the contact surfaces.
During welding, the molten pool must be protected from atmospheric gases such as oxygen and nitrogen, which can cause defects. Protection is provided by shielding gas or flux, depending on the welding method. As the weld pool cools, the molten metal solidifies into a metallurgical bond.
What Is Arc Welding Used For?
Arc welding is widely used in manufacturing, fabrication, construction, and repair work. It plays a critical role in building structures such as bridges, ships, and pipelines, as well as in producing heavy equipment and vehicles. It is also used in aerospace, oil and gas, and infrastructure maintenance.
Beyond industrial applications, arc welding is employed in smaller-scale projects, including custom metalwork, restoration, and automotive repair. Its adaptability to different metals and thicknesses makes it valuable across diverse industries.
Types of Arc Welding
We've tested every major type of arc welding, and each one has strengths that make it ideal for specific situations. Below, we'll break them down so you can see exactly how they work and where they shine:
Consumable Electrode Methods
Gas Metal Arc Welding (MIG/MAG)
MIG and MAG welding use a continuously fed wire electrode that melts into the joint. A shielding gas protects the weld from contamination in the air. MIG welding is typically paired with inert gases like argon for nonferrous metals, while MAG uses active gases such as CO₂ for steel.
This method is fast, efficient, and produces clean welds. It's commonly used in automotive work, fabrication shops, and manufacturing lines where speed matters.
Shielded Metal Arc Welding (SMAW)
Also known as stick welding, SMAW uses a flux-coated electrode rod. The arc melts both the rod and the base material, while the flux forms a protective slag over the weld.
This method is portable, requires minimal equipment, and performs well outdoors, even in windy conditions. It's a go-to choice for construction, maintenance, and pipeline welding.
Flux-Cored Arc Welding (FCAW)
FCAW uses a hollow wire filled with flux. Some variations require an external shielding gas, while self-shielded types rely entirely on the flux. It offers high deposition rates and excels at welding thicker materials.
Flux core welding is often used in shipbuilding, structural steel assembly, and heavy equipment manufacturing.
Submerged Arc Welding (SAW)
In SAW, the electrode and arc are completely covered by a blanket of granular flux. The flux shields the weld, minimizes spatter, and helps produce deep penetration.
This process is highly efficient for large-scale projects such as pressure vessels, heavy plate work, and bridge fabrication.
Non-Consumable Electrode Methods
Carbon Arc Welding (CAW)
CAW uses a carbon electrode to form the arc and melt the base material. While largely replaced by newer processes, it's still used in certain maintenance and heating applications.
It played an important role in the early development of arc welding technology and remains a valuable technique for specific repair tasks.
Gas Tungsten Arc Welding (TIG/GTAW)
TIG welding uses a tungsten electrode that does not melt during welding. Filler metal, if needed, is added separately while the weld is shielded with an inert gas like argon. TIG delivers exceptional precision and is ideal for stainless steel, aluminum, and titanium.
Industries such as aerospace, medical manufacturing, and food processing often rely on TIG for its clean, high-quality results.
Plasma Arc Welding (PAW)
PAW is similar to TIG but creates plasma inside the torch by constricting and ionizing the arc. The plasma jet is focused and extremely hot, allowing for narrow, deep welds with minimal distortion.
It's commonly used for high-spec applications in aerospace and electronics manufacturing.
Tools & Equipment for Arc Welding
Here's what welding tools and equipment you'll need based on our years in the field:
Power Supply (AC or DC)
Every arc weld starts with a reliable power source. It creates the electrical energy needed to strike and maintain the arc. Direct current (DC) is popular for its smoother, more stable arc, which works especially well on thin materials like sheet metal. Alternating current (AC) is useful for certain metals, including aluminum, and helps reduce arc blow during welding.
A good machine should let you adjust amperage to match the material thickness and welding process. We recommend investing in a unit that supports both AC and DC for maximum flexibility.
Electrode & Electrode Cable
The electrode is the heart of the arc. In consumable methods, such as stick or MIG welding, it melts and becomes part of the weld bead.
In non-consumable methods like TIG, the tungsten electrode stays solid while you add filler separately. The electrode cable delivers the current from the machine to the electrode holder or gun.
Good-quality welding cables reduce voltage drop and improve arc stability, so it's worth using heavy-duty leads if you're welding for long periods or at higher currents.
Work Clamp & Ground Cable
A secure electrical connection is essential for safety and weld quality. The work clamp attaches to the workpiece or to the metal table holding your project. The ground cable completes the circuit back to the welder. If the clamp is loose or poorly positioned, you'll get erratic arc performance and weaker welds.
We've found that a spring-loaded or screw-type clamp with clean contact surfaces works best for consistent results.
Shielding (Gas or Flux)
Protecting the molten metal from the air is critical. In MIG and TIG welding, a shielding gas like argon, helium, or a gas mix flows over the weld to block oxygen and nitrogen. In stick, flux-cored, and submerged arc welding, the flux coating or flux-filled wire decomposes to create a shielding gas or a protective slag layer.
Choosing the right shielding medium depends on the process, base metal, and location of the job. For example, flux-core is often preferred outdoors because wind can blow away shielding gas.
Protective Gear
Arc welding produces intense light, heat, and sparks. A proper welding helmet with an auto-darkening lens protects your eyes from UV and infrared radiation. Heat-resistant welding gloves give you the dexterity to handle electrodes or filler rods while guarding against burns.
Flame-resistant clothing, such as a welding jacket or sleeves, keeps your arms and torso safe. We've seen too many people cut corners here only to regret it later. Quality gear is as important as the welder itself.
Optional Fillers & Accessories
Depending on the process, you may need extra consumables. TIG welding often requires filler rods matched to the base material. MIG welding uses wire spools that feed through the gun. Flux-cored and submerged arc welding rely on flux materials or cored wires. Using the right filler ensures strong, clean welds.
Accessories like chipping hammers, wire brushes, and clamps make the workflow smoother and improve finished results. After years of testing different brands, we know that small upgrades in accessories can save a lot of frustration during a project.
Conclusion
Arc welding delivers strength, precision, and adaptability across a wide range of applications, from structural fabrication to detailed metalwork. Understanding how it works, the differences between each process type, and the essential tools involved is critical for producing consistent, high-quality welds.
Selecting the right equipment, matching consumables to the material, and using proper protective gear all contribute to both performance and safety. For dependable, well-tested supplies that meet the demands of any project, purchase your welding gear directly from Badass Welding Products.