Difference Between Arc Welding And Gas Welding

Welding is one connecting process where two or more metal pieces can be linked with or with no heat, pressure, and filler metal. This can be done through arc welding or gas welding. These two types differ in that arc welding uses electricity to generate heat to weld, whereas gas welding uses flammable gases to generate heat.

Apart from gas and arc welding, other types of welding, such as Metal inert gas (MiG)welding and Tungsten inert gas welding (TIG). In MIG welding, a consumable wire electrode is unceasingly fed via the welder and shielding gas. In contrast, TIG welding is formed by heating and melting the metals with a tungsten electrode. Many welders consider TIG welding to be the most difficult of all the types. However, it produces robust, precise outcomes, and that is why it is used for critical projects, such as aerospace construction and vehicle manufacturing.

This has made arc and gas welding popular in many projects—however, the two vary in so many ways. Here the differences are discussed to help you make an informed decision on which one to go for. Keep reading!

Difference Between Arc Welding And Gas Welding

Arc welding VS. Gas Welding

Differences Between Arc Welding And Gas Welding

Arc WeldingGas Welding
Arc welding uses electricity to generate heat.Gas welding uses flammable gases to generate heat.
Arc temperature is high; it exceeds 6000 degrees Celsius. This temperature can melt down any metal.Gas welding temperature is limited to 3300 degrees Celsius, which is lower than arc temperature. This temperature isn’t suitable for joining metals with a high melting point.
This type of welding creates a stronger joint compared to gas welding.It creates a weaker joint.
The filler metal is combined with shielding gas.A filler rod can be used disjointedly.
The risk of explosion occurs due to high voltage.The risk of explosion occurs due to high pressure.
Arc welding is more efficientIt is less efficient
Speed of welding is highSpeed of welding is low
Arc welding gives poor surface finishThis welding gives an excellent surface finish
Few arc welding processes include: Submerged arc welding Shielded metal arc welding Tungsten inert gas welding Gas metal arc welding Flux-cored arc weldingFew gas welding processes include: Oxy-propylene gas welding Air-acetylene gas welding Oxy-acetylene gas welding Oxy-hydrogen gas welding
Arc welding is intended to join comparatively thicker components.Gas welding is preferred for thin plates as well as for sheet metals.
Arc welding processes cannot be functional for cleaning, heating, cutting, etc.Gas welding is applied for joining and post-heating, heat treatment, pre-heating, metal cleaning, soldering, brazing, post-heating, gas cutting, etc.

Heat Generations

Arc welding uses electricity to generate heat for welding metals together. On the other hand, gas welding uses flammable gases to generate heat.  This is the most basic difference between these two types of welding.

Risk Factor

Due to high-voltage, the risk of explosion is high in arc welding. On the other hand, the risk of explosion in gas welding is high because of the high pressure. There is risk involved in these two types of welding, but gas welding is more dangerous than arc welding. You should, therefore, take precautions while welding no matter the type of welding you are using.

Resultant Temperature

Arc welding produces high-temperature as compared to gas welding. The resultant arc temperature is estimated to be around 6000 degrees Celsius while gas welding is limited to generate only 3300 degrees Celsius. With these kinds of resulting temperatures from both processes, there is no doubt the metals will melt quickly and have better penetration and a strong bond.

Speed Of Welding

Arc welding speed is high compared to that of gas welding. This means the production rate of gas welding is low.

Cost Involved

The cost involved in the set up for arc welding is high compared to that of gas welding. But as time goes, you will realize that arc welding is much inexpensive as compared to gas. This is because, in arc welding, you don’t have to purchase a gas cylinder frequently, if at all. Also, arc welding does not necessarily use a shielding gas, which saves much cash.

Resultant Joint

Arc welding makes a stronger joint than gas welding. This is because of the high temperatures linked to arc welding that can melt any metal.

Filler Wire

Arc welding uses filler metal combined with the electrode, whereas, in gas welding, a filler rod is sometimes used separately.


Arc welding is more effective than gas welding. However, that doesn’t mean arc welding is best in all fields.  There are other applications where gas welding is recommended.

What Are Some Of The Similarities Between Arc Welding And Gas Welding?

The following are some of the major similarities between arc welding and gas welding:

1. Both arc welding and gas welding processes trail the same primary principle of fusion welding. In fusion-welding, heat should be applied to melt down the co-components linking surface for the union. It’s good to note that no fusion comes into existence in solid-state welding processes.

2. Arc welding and gas welding are not only intended for homogeneous joining but also heterogeneous joining. However, heterogeneous union happens only after ensuring metallurgical, chemical, and thermal compatibility.

3. In both arc welding and gas welding processes, heat is supplied outwardly.

4. Alteration of metallurgical properties close to the weld bead is intrinsic to all arc welding and gas welding processes.

5. In all arc welding and gas welding processes, filler metal can be supplied outwardly.

What Are The Different Types Of Arc Welding?

Arc welding process can be categorized into two types that is a consumable and non-consumable electrode.

Consumable Electrode Methods:

Gas Metal Arc Welding (GMAW)

This type uses shielding to guard the base metal against contamination.

Shielded Metal Arc Welding (SMAW)

In this type of welding, the arc is hit between the metal rod and the workpiece. After striking, both the metal rod and workpiece surface melt down to form a weld pool. Concurrent melting of the flux welding on the rod will result in gas, and slag, which will, in turn, offer protection of the weld pool from the surrounding atmosphere.  This is a versatile process perfect for connecting ferrous and non-ferrous materials with a variety of material thicknesses.

Flux Cored Arc Welding (FCAW)

This type uses the heat produced by a DC electric arc to fuse the metal in the joint zone. The arc is hit between a continuously fed consumable flux cored electrode and the workpiece. This process either uses the gas created by flux or a shielding gas to offer protection from contamination.

Submerged Arc Welding (SAW)

SAW involves the creation of an arc between a continuously fed consumable electrode and the workpiece. A blanket of fusible flux produces a protective gas shield and slag, which protect the weld zone.

Electro-Slag Welding (ESW)

The ESW process has some submerged-arc welding features in that it is used for welding in the vertical position. This method utilizes bare filler wires fed continuously into a molten slag pool in water-cooled dams.

Arc Stud Welding (SW)

Arc stud welding is a power-driven arc process that rapidly joins a nut or fastener. The fastener can take many forms, including tapped, threaded, unthreaded, and many more.  Both the fastener and nut can be various materials comprising aluminum, steel, stainless steel, etc.

Non-Consumable Electrode Methods:

Gas Tungsten Arc Welding (GTAW)

This is created by heating and melting the metal with a non-consumable tungsten electrode. The method uses an inert shielding gas to protect the weld zone.

Plasma Arc Welding (PAW)

Plasma arc welding is similar to TIG welding as it is formed between a non-consumable electrode and a workpiece. However, by positioning the electrode within a torch’s body, the plasma arc can be separated from the shielding gas.

Which Type Of Welding Is The Strongest?

TIG welding creates cleaner and more precise welds when compared to MIG welding or other types of welding, making it the strongest.

Which Gas Is Used For Arc Welding?

Helium and argon are the only noble gages, which are cost-effective to be used in arc welding. These two gases are used in gas tungsten arc welding (TIG) and gas metal arc welding to fuse non-ferrous metals.

What Are The Advantages And Disadvantages Of Arc Welding?


1. Portability- materials linked to arc welding are effortless to transport

2. Cost- equipment for arc welding is cheaper, and the process frequently needs less equipment; you know why? Because of the lack of gas.

3. Shielding gas isn’t necessary


1. Operators for arc welding requires a high level of skills and training

2. Lower efficiency- more waste is usually created during arc welding compared to other types, which can in turn increase project cost

3. It can be challenging to use arc welding on thin materials

Final Word

As you have seen, there are some differences between gas welding and arc welding. If you are at a purchase point and need to know which will work best for you, you ought to look at your work requirements. Read the article keenly to see what you need and which of the two types fulfill your requirements.

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