Welding processes differ in precision, heat input and economy. What matters is not the process alone, but how it is applied. Using typical examples, we show when each process is appropriate.
Without the Right Filler, No Stable Solution.
Alongside the process, the welding filler plays a central role. It fundamentally determines the properties of the joint or coating.
capilla offers welding fillers for a wide range of applications – matched to the material, process and operating conditions.
Automated Welding Processes at the capilla LCC
At the Laser Competence Centre, capilla brings together modern technologies for automated coating and manufacturing.
Here, components are selectively built up, heat-treated and optimised using laser-based processes. Processes, material deposition and results can be precisely controlled.
This creates solutions that go beyond conventional welding processes and cannot be achieved with standard approaches.
Finding the Right Process
Are you unsure which welding process is suitable for your application?
We support you in selecting and combining the right processes.
Frequently Asked Questions about Welding Processes
Welding processes are standardised methods for joining two or more workpieces by material bonding, or for applying a functional layer by overlay welding. The processes differ in energy source (e.g. arc, gas, laser), shielding medium and type of filler material. In industry, the arc welding processes TIG, MAG and manual metal arc welding have become most widely established.
The most common welding processes are manual metal arc welding (111), MAG welding (135) and TIG welding (141). Manual metal arc is the classic process for repair work and site applications, MAG dominates in industrial fabrication of steel structures, and TIG is the process for the highest quality requirements on stainless steel, aluminium and thin-walled components. All three are fusion welding processes.
The numbers come from DIN EN ISO 4063, which uniquely identifies each welding process. 111 stands for manual metal arc welding with coated electrodes (MMA/SMAW). 135 stands for metal active gas welding (MAG). 141 stands for tungsten inert gas welding (TIG). The numbers are used in welding procedure specifications, test certificates and filler material specifications.
Welding types describe the overarching process category, for example fusion welding or pressure welding. Welding processes are the specific methods within a welding type, for example TIG, MAG or manual metal arc as fusion welding processes. The welding type classifies the technology; the welding process is the specific application.
TIG is used when the highest weld quality is required, for example on stainless steel, aluminium and thin-walled components. MAG is used for economical welding of steel in series production and structural steelwork. Manual metal arc is the first choice for repair work, site conditions and wherever flexibility is more important than high deposition rates. The choice depends on material, component size, weld quality requirements and location.
TIG is the right choice for high demands on weld quality and appearance, MAG for high throughput in steel fabrication, and manual metal arc for repair, assembly and mobile applications. As a rule of thumb: the thicker the component and the higher the deposition volume, the more appropriate MAG. The thinner and more demanding the application, the more appropriate TIG. The more flexible and location-independent the task, the more appropriate manual metal arc.
TIG is suitable for almost all materials, particularly stainless steel, aluminium, titanium and nickel-based alloys. MAG is designed for unalloyed and low-alloy steels, and with the appropriate gases also for stainless steel. Manual metal arc covers unalloyed and low-alloy steels, stainless steel, cast iron and many special alloys. Material compatibility depends on the correct choice of filler material.
For repair welding, manual metal arc is the most widely used process because it is flexible and virtually independent of the component location. For overlay welding, MAG with flux-cored wires is also used when larger areas need to be hard-faced, for example on wear parts. TIG is used for overlay welding when particularly fine and controlled layers are required, for example on valve seat faces.
The welding process determines how the hard overlay can be applied and what layer thickness, layer homogeneity and dilution with the base material are achievable. MAG with flux-cored wires is the most economical option for large-area wear protection, manual metal arc offers maximum flexibility for on-site repairs, and TIG allows precise layers on critical functional surfaces. The process and filler material must be matched to each other and to the type of wear.
The right welding process depends on material, component, weld quality requirements and location. There is no single best process, but for every application there is a technically and economically sound choice. For a well-founded decision, a component analysis is recommended in which load, material and function are defined together with the appropriate welding process and filler material.