Welding Processes Compared: SMAW, GMAW, FCAW, GTAW and SAW
Compare the main steel welding processes: stick (SMAW), MIG/MAG (GMAW), flux-cored (FCAW), TIG (GTAW) and submerged arc (SAW) — speed, quality, positions, site vs shop use.
Saudi Steel Work Editorial Team · · 3 min read
Short answer: SMAW (stick) is versatile and good for site work; GMAW (MIG/MAG) is fast and clean for shop fabrication; FCAW (flux-cored) offers high deposition and good outdoor performance with self-shielded wires; GTAW (TIG) gives the highest quality for thin material, stainless and root passes; SAW (submerged arc) gives very high deposition for long, heavy shop welds such as plate girders.
Each arc welding process has strengths. Fabricators choose based on material, thickness, position, location and quality requirements.
Overview
| Process | Common name | Shielding | Speed | Best for |
|---|---|---|---|---|
| SMAW | Stick | Flux coating | Low–medium | Site work, repairs, all positions |
| GMAW | MIG/MAG | External gas | High | Shop fabrication, thin–medium plate |
| FCAW | Flux-cored | Flux core ± gas | High | Structural, outdoor (self-shielded) |
| GTAW | TIG | Inert gas | Low | Stainless, thin sheet, pipe roots |
| SAW | Submerged arc | Granular flux | Very high | Long, heavy welds (girders, tanks) |
SMAW (stick)
- Simple, portable equipment
- Works outdoors and in wind
- Electrode choice matters (E6013 vs E7018)
- Slower; slag removal between passes
GMAW (MIG/MAG)
- Continuous wire (e.g. ER70S-6) with CO₂ or argon mixes
- Fast and clean, minimal slag
- Sensitive to wind — mainly shop use
FCAW
- Tubular wire with flux core (e.g. E71T-1)
- Gas-shielded for shop; self-shielded for site
- High deposition, good for structural fillet welds
GTAW (TIG)
- Non-consumable tungsten electrode, separate filler
- Excellent control and appearance
- Standard for stainless and pipe root passes
- Slow and skill-intensive
SAW
- Arc under a blanket of flux
- Very high deposition, deep penetration, excellent quality
- Mechanised; flat and horizontal positions
- Used for plate girders, tank seams, pipe mills
Quality control
Whatever the process, welding must follow qualified procedures with qualified welders (WPS, PQR and welder qualification) and be inspected (NDT for steel).
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