Fusion Welding: Its Types, Advantages and Disadvantages

Welding is an essential part of any project, whether it is big or small. No sturdy structures can be built without performing good welding. We might think that welding might be something which is a pretty simple thing, but in reality, there are many variations of welding that are used in different scenarios.

Welding is the process of joining two pieces of metal together. There are many different welding methods, but fusion welding is one of the most popular. Fusion welding is a very common type of welding, and it can be used on many different types of metals. This form of welding is a very versatile method and can be used for a variety of applications.

In this article, we will discuss everything about fusion welding, 7 of its types and also differentiate fusion welding from non-fusion welding. So without any further ado, let’s get started.

What is Fusion Welding?

What is Fusion Welding

Fusion welding is a type of welding that uses heat to melt and join two pieces of metal together. The heat for fusion welding can come from an electric arc, a laser, or an electron beam. Fusion welding is used to create everything from small objects like jewelry to large structures like bridges.

There are many different types of fusion welding, but they all have one thing in common: they use heat to melt the metals being joined together. This melting point is called the weld pool. Once the weld pool cools, the metals will be joined together permanently.

The Comparison Between Fusion Welding and Non-Fusion Welding

Fusion welding commonly uses heat to melt and join the pieces of metal. The molten metal then cools and forms a strong bond between the two pieces. Non-fusion welding, on the other hand, does not use heat to weld two pieces of metal together. Instead, it relies on pressure or adhesive to hold the two pieces together.

There are several differences between fusion and non-fusion welding. For instance, fusion welding is generally stronger than non-fusion welding, but it can be more difficult to control the heat when fusion welding. Non-fusion welds are typically less expensive than fusion welds, but they may not be as strong or durable.

Ultimately, the type of welding you choose will depend on your project requirements and your budget. If you need a strong, durable bond, fusion welding is likely the best option. However, if cost is a concern, non-fusion welding may be a better choice.

7 Different Types of Fusion Welding

Fusion welding is a type of welding that joins two pieces of metal together by melting and fusing them. There are several different types of fusion welding, each with its own benefits and drawbacks. The 7 most common types of fusion welding are:

Oxyacetylene welding

Oxyacetylene welding

Oxyacetylene welding, also known as gas welding, uses a flame produced by burning a mixture of oxygen and acetylene to melt and fuse the metals together. This method of fusion welding is relatively inexpensive and easy to learn, but it is not very efficient and can be extremely hazardous if not done properly.

Arc welding

Arc welding, also known as stick welding, uses an electric arc to create heat that melts the metals being joined. This type of fusion welding is more efficient than oxyacetylene welding and is less likely to cause accidents, but it is more expensive and requires more training to learn.

Metal Inert Gas (MIG) Welding

MIG welding, or metal inert gas welding, uses a stream of argon or other inert gas to protect the weld from contamination. This type of welding is very efficient and produces high-quality welds, but it is also very expensive.

Metal Active Gas (MAG) Welding

MAG welding is a type of arc welding that uses a wire electrode to create an electric arc. The arc melts the metal and the filler material, which are then joined together. MAG welding is used in many industries, including automotive, aerospace, and construction.

Tungsten Inert Gas (TIG) Welding

TIG welding, or tungsten inert gas welding, uses a tungsten electrode to create the arc that melts the metals being joined. This form of fusion welding produces extremely high-quality welds, but it is also very difficult to learn and can be quite dangerous if not done properly.

Electron Beam Welding (EBW)

EBW is a fusion welding process that uses a high-energy beam of electrons to weld metals together. The beam melts the metals, which then flow together and form a strong bond. EBW is often used for welding thin sheets of metal together, as it can create very strong bonds without adding much heat to the surrounding area.

EBW is a very precise welding process, which makes it ideal for joining together delicate parts or components. It can also be used to weld metals that are difficult to weld using traditional methods, such as aluminum. EBW is often used in the aerospace and automotive industries, where precision and strength are essential.

Laser Beam Welding LBW

Laser Beam Welding

Laser beam welding is an advanced type of fusion welding that uses a laser to heat the material being joined. The laser beam is focused onto the surface of the material, causing it to melt and form a weld. LBW can be used to join metals, plastics, and other materials.

LBW is often used for joining thin pieces of metal together, as the laser beam can be focused onto a very small area. This makes it ideal for welding delicate parts or components that cannot be heated with traditional methods. LBW is also used for joining dissimilar materials, such as aluminum and steel. The high heat of the laser beam can melt both metals, allowing them to form a strong bond.

LBW is a versatile welding method that can be used in a variety of applications. It is most commonly used in industries where complex welding is required. This is also used in medical device manufacturing. LBW can be performed manually or automated, making it suitable for both small and large-scale production.

These are the different types of fusion welding that are available out there. It’s essential to consult an expert before choosing your desired welding method.

What are the Advantages of Fusion Welding?

Fusion welding is a process that joins two pieces of metal together by using heat to melt the metals at their joint. This type of welding has several advantages over other methods, such as resistance welding and oxy-fuel welding.

One advantage of fusion welding is that it can be used on a variety of metals, including aluminum, stainless steel, and cast iron. Moreover, it can also be used to weld plastic pipes. This makes it a versatile option for many different projects.

Another advantage of fusion welding is that it produces a strong bond between the two pieces of metal. The heat from the weld melts the metals and creates a molten pool where the metals mix together. As the pool cools, it forms a single piece of metal with a strong bond.

Fusion welding is also a relatively fast process. It can be completed in a matter of minutes, which is much faster than other methods such as oxy-fuel welding.

Overall, fusion welding is a versatile, strong, and fast method for joining two pieces of metal together. It has many advantages over other methods and is the preferred method for many different projects.

What are the Drawbacks of Fusion Welding?

Fusion welding is not without its drawbacks. One of the biggest issues is that it can be very difficult to control the heat, which can lead to warping or even melting of the materials being joined. This means that fusion welding requires a great deal of skill and experience to do correctly.

Another potential problem with fusion welding is that it can create very high levels of stress in the materials being joined. This stress can sometimes lead to cracking or even breaking of the welded joint over time.

Despite these drawbacks, fusion welding remains one of the most popular methods for joining metals together. When done correctly, it can create strong, durable joints that will last for many years. With proper care and maintenance, fusion welded joints can provide years of trouble-free service.

If you are considering fusion welding for your next project, be sure to consult with an experienced welding professional to ensure that the job is done correctly.

Few Things to Keep in Mind Before Fusion Welding

Before fusion welding, there are a few key things you need to keep in mind. First, it is important to have a clean and well-prepared surface. Any dirt or debris on the surface can cause problems with the weld. Second, you need to make sure that the two pieces you are welding are properly aligned.

If they are not aligned correctly, the weld will be weaker and more likely to break. Finally, you need to use the right type of welding rod for the material you are welding. Using the wrong type of rod can lead to a poor weld or even damage the material.

By keeping these things in mind, you can ensure that your fusion weld is strong and looks great.


So, what have we learned about fusion welding? Let’s recap. Fusion welding is a process that uses heat to join two pieces of metal together. The heat is applied to the edges of the metals until they reach their melting point, and then they are fused together. This creates a strong weld that is able to withstand a lot of stress.

In order for fusion welding to be successful, you need to make sure that your surfaces are clean and free of any contaminants. You also need to use the right type of electrode for the job. If you follow these steps, you should be able to create a strong weld every time.

Hi! My name is Josh Mathews and I’m a professional welder residing in the state of Texas. As I’m a writer by heart, I believe it would be wonderful to share the knowledge I’ve gained over the years working in the welding industry, which worked as my initial motivation. I want others who read through our blogs to get inspired and enter the welding scene one day.

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