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RentArc Welding FAQs: What Factors to Consider When Selecting a Welding Process?

At RentArc we are always looking to help our customers in any way we can.

To this end, we are putting together a new series blogs around welding, designed to answer questions from those new to the industry, alongside those who are seasoned pros. Over 2024, we will be taking your questions and providing answers as part of our new Welding FAQs blog.

First up, to get us started, we are tackling the question ‘What factors should I consider when selecting a welding process?’

With multiple welding processes available, each with its advantages and limitations, selecting the right one is clearly important for achieving the desired quality, efficiency and cost-effectiveness. This blog explores the key factors you should consider when selecting your welding process.

Material Type

The first and foremost consideration is the type of materials you intend to join. Different welding processes are suitable for different materials. For example, TIG (Tungsten Inert Gas) welding is often used for thin materials and high-quality welds in stainless steel, aluminium, and non-ferrous metals, while MIG (Metal Inert Gas) welding is versatile for both thick and thin materials, including steel and aluminium. Which applies to your welding situation?

Thickness of the Materials

Next up is the thickness of the materials to be welded. This significantly influences the choice of welding process. Stick welding, for example, is effective for thicker materials, whereas laser welding might be better for precision joining of thin materials.

Desired Weld Quality

Weld quality encompasses strength, appearance and durability. Processes like TIG welding provide high-quality, precise welds with excellent finish, making them ideal for applications where aesthetics are important or in industries like aerospace where weld integrity is critical.

Cost Considerations

Cost is clearly a multifaceted factor, including elements like equipment, material, labour, alongside operational costs. Some welding processes require more expensive equipment or consumables. For example, laser welding equipment is typically more costly than traditional arc welding setups. Additionally, the skill level required for certain processes can affect labour costs.

Production Volume and Efficiency

Your production volume and efficiency targets can dictate the appropriate welding process too. For high-volume production, automated welding processes like robotic welding might be more suitable. For lower volumes or custom work, manual processes like TIG or stick welding might be more cost-effective.

Accessibility and Position of the Weld

The position of the weld and accessibility of the joint also play a crucial role. Some welding processes, such as stick welding, offer more flexibility in welding positions and are more adaptable to confined spaces, compared to processes like submerged arc welding, which is typically used in bench welding applications, where the pieces can be easily positioned.

Safety and Environmental Considerations

Safety is paramount in welding, requiring those involved to be protected from heat, sparks, and harmful emissions. Processes like MIG and TIG welding produce less fumes compared to stick welding, making them preferable in environments where ventilation is a concern.

What is right for you?

Clearly, choosing the right welding process requires a good understanding of the specific requirements of your project. By considering the material type, weld quality, cost, production volume, weld position and safety requirements, you can select a welding process that ensures optimal performance, efficiency and cost-effectiveness. Remember, consulting with welding experts and conducting tests can also provide valuable insights into the most suitable process for your needs and that is where the RentArc team are happy to help. If you have any questions about the right welding equipment for your project, get in touch.

You can call us on +44 (0)23 80 867 789 or email us at


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