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Fusion vs Non-Fusion Welding – What’s the Difference

Fusion vs Non-Fusion Welding

In the metalworking industry, welding is a critical technique for connecting two pieces of metal. Depending on the metal or alloy you are working with, two types of welding methods are used to join metals—fusion welding and non-fusion welding. Let’s take a deeper look at these two methods so you can select the right one for your project.

Fusion Welding

Fusion welding is the most commonly used type of welding process. It requires more skill than non-fusion welding but offers more strength and durability. This method works by melting both pieces of metal at high temperatures until they form one single piece. The most common fusion welds are MIG (inert metal gas) and TIG (inert tungsten gas). MIG uses a consumable electrode wire that feeds electric current to the arc. In contrast, TIG uses an electrical arc and a non-consumable tungsten electrode to heat the weld. Both processes require shielding gases like argon or helium to keep oxygen out of the weld pool to prevent oxidation.

Non-Fusion Welding

Non-fusion welding is a process that relies on pressure, not heat, to bind two pieces of metal together. This method is ideal for joining metals with low melting points, such as stainless steel, aluminum, copper, and magnesium, because they will not melt during this process. There are several types of non-fusion welds, including friction stir spot welding (FSW), diffusion bonding, cold pressure welding (CPW), ultrasonic spot/projection/seam welding (USW), and resistance spot/butt/projection welding (RSW). Each type has unique advantages depending on what kind of project you’re working on.

Difference Between Fusion and Non-Fusion Welding

Types of Welding

There are two main types of welding: fusion welding and non-fusion welding. Fusion welding is a type of welding that involves melting two pieces of metal that are being joined together. Non-fusion welding, on the other hand, does not involve melting the metal.

Methods of Welding

There are various fusion welding methods, including gas, arc, and laser welding. Gas welding is a type of welding that uses a flame to heat the metal. Arc welding is a type of welding that uses an electric arc to heat the metal. Laser welding is a type of welding that uses a laser to heat the metal.

Advantages of Fusion Welding

Fusion welds are stronger than non-fusion welds because the metal is melted and then cooled, creating a stronger bond. Fusion welds are also less likely to leak than non-fusion welds.

Disadvantages of Fusion Welding

Fusion welds can be more difficult to create than non-fusion welds because the metal needs to be melted without burning through it. Fusion welds can be more expensive than non-fusion welds because they require more specialized equipment.

Applications of Welding

Welding is used in various applications, including automotive manufacturing, shipbuilding, and pipeline construction.


When selecting a suitable type of weld for your project, the choice between fusion and non-fusion will depend on the metals or alloys being joined together and your desired outcome. Fusion welding offers greater strength but requires more skill and specialized tools, while non-fusion welding does not require extreme temperatures but specific techniques depending on which method you use. Whichever option you choose, it’s essential to understand how each type works to select the best one for your needs!

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