The choice of welding process determines the quality, speed and cost of the work. Each process has its own advantages and limitations. Below we review the four most common processes in industrial assembly and the manufacture of steel structures, and when we choose each one.
MMA — manual metal arc welding (111)
Welding with a coated electrode is the most versatile and least sensitive to site conditions — it works outdoors, in wind and in hard-to-reach positions. That is why it remains the first choice for site assembly and repairs.
The downside is lower productivity and the need to remove slag, so for long, series welds it is often less suitable than gas-shielded processes.
MIG/MAG — wire welding under shielding gas (135/136)
MAG (135 with solid wire, 136 with flux-cored wire) is the workhorse of industrial production: fast, productive and suitable for automation. It is used for structural steels, from thin plate to thicker sections.
It requires better protection from draughts than MMA, so it is mainly suitable for work in the workshop or in enclosed spaces.
TIG — tungsten inert gas welding (141)
TIG produces the cleanest and most precise welds, so it is indispensable for stainless steels, aluminium, pipelines and wherever appearance and leak-tightness are key. It gives excellent control over the weld pool.
It is slower and requires more experience, so we use it where quality outweighs speed — for example in the process and food industries.
SAW — submerged arc welding
SAW is intended for long, straight and thick welds — for example on large steel structures, vessels and bridges. The arc is hidden under a layer of flux, which enables high productivity and deep penetration with minimal spatter.
The process is largely mechanised and tied to workshop conditions and suitable equipment.
How we choose the right process
The decision depends on a combination of factors:
- Material and thickness (steel, stainless, aluminium)
- Location of work — workshop or site
- Required quality and weld appearance
- Volume and series (single piece or batch)
- Deadline and available equipment
In practice
In real projects we often combine processes — for example SAW for the main seams in the workshop and MMA for assembly on site. Our certified welders master all four processes, which means we choose the most suitable one for each part.