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Table 1.1 summarizes the fusion welding processes recommended for carbon steels, low‐alloy steels, stainless steels, cast irons, nickel‐base alloys, and aluminum alloys [3]. For one example, GMAW can be used for all the materials of almost all thickness ranges while GTAW is mostly for thinner workpieces. For another example, arc welding processes that require the use of a flux, such as SMAW, SAW, FCAW, and ESW, is not used for aluminum alloys.

Table 1.1 Overview of welding processes. Source: Welding Handbook [3], vol 1, 7th edition, © American Welding Society.

		Joining processa
Material	Thicknessb	SMAW	SAW	GMAW	FCAW	GTAW	PAW	ESW	OFW	EBW	LBW
Carbon steels	S	x	x	x		x			x	x	x
I	x	x	x	x	x			x	x	x
M	x	x	x	x				x	x	x
T	x	x	x	x			x	x	x
Low‐alloy steels	S	x	x	x		x			x	x	x
I	x	x	x	x	x				x	x
M	x	x	x	x					x	x
T	x	x	x	x			x		x
Stainless steels	S	x	x	x		x	x		x	x	x
I	x	x	x	x	x	x			x	x
M	x	x	x	x		x			x	x
T	x	x	x	x			x		x
Cast iron	I	x							x
M	x	x	x	x				x
T	x	x	x	x				x
Nickel and alloys	S	x		x		x	x		x	x	x
I	x	x	x		x	x			x	x
M	x	x	x			x			x	x
T	x		x				x		x
Aluminum and alloys	S			x		x	x		x	x	x
I			x		x				x	x
M			x		x				x
T			x						x

^a) Process code: SMAW, shielded metal arc welding; SAW, submerged arc welding; GMAW, gas−metal arc welding; FCAW, flux cored arc welding; GTAW, gas–tungsten arc welding; PAW, plasma arc welding; ESW, electroslag welding; OFW, oxyfuel gas welding; EBW, electron beam welding; LBW, laser beam welding.

^b) Thickness: S, sheet, up to 3 mm (1/8 in.); I, intermediate, 3−6 mm (1/8−¼ in.); M, medium, 6−19 mm (¼−¾ in.); T, thick, 19 mm (¾ in. and up); X, recommended.