---
title: Advantages and disadvantages of welding as a joining method - Forgeway Ltd
description: Welding is one of the most popular methods of joining metals. However, there are several reasons why you might now want to use it for your application
image: https://www.forgeway.com/hubfs/Welding-as-joining-method.jpg
---

[![Learning Center Banner](https://www.forgeway.com/hubfs/become-an-adhesive-expert-light-blue-banner.jpg) ](https://www.forgeway.com/learning/fundamentals-of-adhesives-ebook)

[«  View All Posts](https://www.forgeway.com/learning/blog)

# Advantages and disadvantages of welding as a joining method

[Migelo Buckley | 3 min. read](https://www.forgeway.com/learning/blog/author/migelo-buckley)

![Advantages and disadvantages of welding as a joining method](https://www.forgeway.com/hubfs/Welding-as-joining-method.jpg)

Welding replaced mechanical fasteners as the joining method of choice in the 20th century. But as technology advances, companies are looking away from using welding as their primary joining method. You are reading this article because you want to know whether you should use welding, or look at other joining methods.

You’re in luck. As industrial adhesive manufacturers, we often come across instances where manufacturing companies are deciding whether to use welding or not. We know that there are certain advantages and disadvantages to welding.

This article will discuss both the advantages and disadvantages of welding. But just so you are aware, we will be discussing metal-to-metal joining in this article. Whilst you can weld plastic too, plastic welding is different and we would never recommend plastic welding where you require a strong joint.

By the end of this article, you will have a better understanding of metal-to-metal welding. You will become more informed about this joining method. We aim to help you make an informed decision about using welding for your application.

## What are the advantages of welding?

Before we dive into the advantages of welding, we should clarify that we are comparing welding against other joining methods such as mechanical fasteners and structural adhesives. These are the [two main alternatives to welding](https://www.forgeway.com/learning/blog/mechanical-fasteners-or-adhesives-best-joining-method).

Now to find out why welding has been so popular over the years.

### Welding creates a high-strength joint

Although some [structural adhesives](https://www.forgeway.com/learning/blog/what-are-structural-adhesives) are fast catching up, no other joining method can achieve such high strength as welding. This is because the welder melts the two metal surfaces and interlinks the two substrates. 

Sometimes, the weld joint is so strong it becomes stronger than the metal itself. So if you want the highest-strength joint possible, welding is the joining method capable of achieving such high strengths.

![Welding causes a high strength bond](https://www.forgeway.com/hs-fs/hubfs/Imported_Blog_Media/Weld-Example-300x245-1-Apr-30-2024-12-23-01-3508-PM.jpg?width=486&height=397&name=Weld-Example-300x245-1-Apr-30-2024-12-23-01-3508-PM.jpg)

### Welding creates a permanent joint

Whilst having a reversible joint is sometimes beneficial, a permanent joint means the metals cannot be removed once joined. A permanent joint gives you the peace of mind that no one or nothing can tamper with your joint to cause it to come apart.

The only way the joint can come apart is if you designed the joint incorrectly, causing joint failure.

### Welding doesn’t cause structural damage

With most types of mechanical fasteners, you will need to drill holes into the metal to secure them. These holes can cause structural damage and can even [cause corrosion](https://www.forgeway.com/learning/blog/prevent-filiform-corrosion) in the long term.

On the other hand, welding will not cause structural damage. You do not need to pre-drill holes into the metal. Therefore, welding does not increase the risk of metal corroding and will not weaken the metal.

![Rivets can be used instead of welding](https://www.forgeway.com/hs-fs/hubfs/Imported_Blog_Media/rivets-sheet-metal-Apr-30-2024-12-24-14-5518-PM.jpg?width=680&height=453&name=rivets-sheet-metal-Apr-30-2024-12-24-14-5518-PM.jpg)

Rivets can stretch the metal

## What are the disadvantages of welding?

This section will discuss the disadvantages of welding as a joining method against mechanical fasteners and structural adhesives.

### You will struggle to find qualified welders

Welding requires qualified workers. But [there is a severe shortage of skilled welders](https://www.summitsteelinc.com/resources/blog/welder-shortage-impact/) at the moment. Coded welders are not only expensive, but they are hard to find too. 

Mechanical fasteners and structural adhesives do not require the same level of skilled labour. [Unless you are Din 6701/2304 certified](https://www.forgeway.com/learning/blog/din-6701-and-din-2304-explained), then you may have to train the operative who is applying the adhesive. However, welding is the only joining method that requires highly-skilled labour.

![Qualified welders are hard to find](https://www.forgeway.com/hs-fs/hubfs/Imported_Blog_Media/LEV-system-in-factory-4.jpg?width=629&height=440&name=LEV-system-in-factory-4.jpg)

### Welded joints can’t withstand vibrations

Welded joints will not have much flexibility. So, if the joint is going to experience a lot of movement (like in a transportation/automotive application), you may experience joint failure. 

This is because metal isn’t a flexible material. When there are vibrations caused by the moving vehicle, the metal (and the weld) will not be able to absorb any of that movement. This means that the vibrations aren’t dampened.

On the other hand, structural adhesives [can have high strength as well as flexibility](https://www.forgeway.com/learning/blog/strength-v-flexibility-what-is-more-important-in-an-adhesive). This means the adhesive absorbs any vibrations or impact rather than putting a strain on the metal. 

Mechanical fasteners will have the same problem as welding. They aren’t able to flex when experiencing movement. Sometimes, the stress can cause the mechanical fastener to ‘stretch’ the metal around the hole.

In summary, welding will not be able to absorb any vibrations or impact. It is not the ideal joining method where the joint will experience movement (or dynamic load).

### Welding can distort the metal

The heating and cooling process from welding can cause [the metal to distort](https://www.lincolnelectric.com/en/welding-and-cutting-resource-center/welding-how-tos/weld-distortion#:~:text=Distortion%20in%20a%20weld%20results,one%20side%20to%20the%20other.). Whilst most experienced and coded welders should know how to avoid welding distortion, it is still a potential risk.

Welding distortion is a problem for two reasons:

1. It can cause a weak joint
2. It can affect the aesthetics

Welding is the only joining method that requires a severe amount of heat. Therefore, it is the only joining method that will cause the metal to distort in this manner.

![Welding distortion can impact the heat from metals](https://www.forgeway.com/hs-fs/hubfs/Imported_Blog_Media/Welding-distortion-1.png?width=568&height=355&name=Welding-distortion-1.png)

## Should you use welding for your application?

So now you know the advantages and disadvantages of welding, you want to know whether you should use welding or look at an alternative joining method.

As industrial adhesive manufacturers, we cannot answer that question for you. We would say that if you are able to find the labour and don’t have a joint that will experience a lot of movement, you should definitely explore welding further. 

However, if you don’t have the money or resource to find a highly skilled welder or you have a join that is going to experience movement, we would suggest looking at alternative joining methods.

As we have already mentioned, mechanical fasteners and structural adhesives are the two most common alternatives to welding.

Have a read of the article below to find out more about the alternatives to welding.

[![Alternatives to welding](https://no-cache.hubspot.com/cta/default/2714415/abf8bbc7-53e6-4c14-b0ff-de96eaa4257e.png)](https://cta-redirect.hubspot.com/cta/redirect/2714415/abf8bbc7-53e6-4c14-b0ff-de96eaa4257e)

<https://www.forgeway.com/learning/blog/author/migelo-buckley>

[ Migelo Buckley ](https://www.forgeway.com/learning/blog/author/migelo-buckley)

Migelo turns technical jargon into clear, easy-to-read content. Forgeway’s mission is to address every question our customers and prospective clients have, even the ones they might hesitate to ask.

 Connect: 

<https://www.linkedin.com/in/migelangelo-buckley-50b905189/> [mailto:migelo.buckley@forgeway.com](mailto:migelo.buckley@forgeway.com)

 Topics:

[ Bus and Coach ](https://www.forgeway.com/learning/blog/topic/bus-and-coach)

[ Commercial Vehicles ](https://www.forgeway.com/learning/blog/topic/commercial-vehicles)

[ Aerospace ](https://www.forgeway.com/learning/blog/topic/aerospace)

[ Article ](https://www.forgeway.com/learning/blog/topic/article)

## Related Articles

[### Formoa 2-30 IQ Review: Two Component Hybrid Polymer

 November 27th, 2024|5 min. read 

](https://www.forgeway.com/learning/blog/formoa-2-30-iq-review)

[### Consistently Building Better Vehicles; The Four Pillars of Successful Bonding in Vehicle Manufacturing

 January 18th, 2024|7 min. read 

](https://www.forgeway.com/learning/blog/the-four-pillars-of-bonding-success)

[### How to Reduce Operator Bonding Error in Industrial Vehicle Manufacturing

 January 9th, 2024|5 min. read 

](https://www.forgeway.com/learning/blog/reduce-operator-bonding-error)

[### Bonding Stainless Steel to Stainless Steel Tips, Tricks, and Considerations for a strong bond

 December 19th, 2023|6 min. read 

](https://www.forgeway.com/learning/blog/tips-for-bonding-stainless-steel-to-stainless-steel)

[### Bonding Composite Materials like GRP and Carbon Fibre; Tips and tricks

 November 13th, 2023|5 min. read 

](https://www.forgeway.com/learning/blog/bonding-composite-materials-grp-and-carbon-fibre)

[### Methyl methacrylate adhesives; definition, pros and cons, and cost

 September 29th, 2023|5 min. read 

](https://www.forgeway.com/learning/blog/what-is-methyl-methacrylate-adhesive)

[### Plastic Bonding; Essential tips and tricks to help you achieve a strong bond with plastic glue

 August 25th, 2023|12 min. read 

](https://www.forgeway.com/learning/blog/plastic-bonding-101-guide)

[### Webinar FAQs: Plastic Bonding Masterclass questions answered

 August 23rd, 2023|2 min. read 

](https://www.forgeway.com/learning/blog/plastic-bonding-masterclass-webinar-faq)

[### Case Study: How Forgeway helped GBM Ltd. cut costs by improving stock control and reducing lead times

 August 17th, 2023|3 min. read 

](https://www.forgeway.com/learning/blog/case-study-forgeway-helping-gbm-improve-profitability)

[### Navigating Structural Adhesive Choices: Comparing Epoxy v Acrylic v Polyurethane Adhesive Formulations

 August 17th, 2023|4 min. read 

](https://www.forgeway.com/learning/blog/epoxy-v-acrylic-v-polyurethane-structural-adhesives)

[### Bonding Powdercoated Materials: Tips and tricks to achieving a high strength bond

 July 21st, 2023|7 min. read 

](https://www.forgeway.com/learning/blog/tips-for-bonding-powder-coat-materials)

[### Video: Bonded Bus Series – EPISODE 4: Gluing the Floor

 July 18th, 2023|1 min. read 

](https://www.forgeway.com/learning/blog/video-bonded-bus-series-episode-4-gluing-the-floor)

[### Video: Bonded Bus Series – EPISODE 3: Gluing the Sidewalls

 July 18th, 2023|1 min. read 

](https://www.forgeway.com/learning/blog/video-bonded-bus-series-episode-3-gluing-the-sidewalls)

[### Video: Bonded Bus Series – EPISODE 2: Gluing the Side Panels

 July 18th, 2023|0 min. read 

](https://www.forgeway.com/learning/blog/video-bonded-bus-series-episode-2-gluing-the-side-panels)

[### Video: Bonded Bus Series – Episode 1: The Windshield

 July 18th, 2023|1 min. read 

](https://www.forgeway.com/learning/blog/video-bonded-bus-series-episode-1-the-windshield)

[### Speeding up production; Is a faster-curing adhesive always the best solution?

 July 11th, 2023|6 min. read 

](https://www.forgeway.com/learning/blog/will-faster-curing-adhesive-speed-up-production)

[### Adhesive’s Temperature Resistance: What is it and how can you measure it?

 June 26th, 2023|6 min. read 

](https://www.forgeway.com/learning/blog/adhesive-temperature-resistance)

[### Decoding Adhesive Terminology: Analysing the Difference Between Toughened, Flexible, and Rigid Adhesives

 June 19th, 2023|4 min. read 

](https://www.forgeway.com/learning/blog/comparing-flexible-v-rigid-v-toughened-adhesives)

[### The Role of Durability in Adhesive Selection: A Guide for Manufacturers and Engineers

 May 12th, 2023|6 min. read 

](https://www.forgeway.com/learning/blog/the-role-of-durability-in-adhesive-selection)

[### Less Weight, More Efficient Vehicles: What to Consider when Using Adhesives to Lightweight Vehicles

 May 4th, 2023|5 min. read 

](https://www.forgeway.com/learning/blog/what-to-consider-when-using-adhesives-to-lightweight-vehicles)

[### What is Forgeway’s Bonding Risk Matrix? Can it benefit your Company?

 March 24th, 2023|4 min. read 

](https://www.forgeway.com/learning/blog/understanding-the-adhesive-bonding-matrix)

[### Video: Exploring the Alternatives to Polyurethane Adhesives

 March 22nd, 2023|0 min. read 

](https://www.forgeway.com/learning/blog/video-alternatives-to-polyurethane)

[### Video: Understanding the Diisocyanate Restrictions 2023

 March 14th, 2023|0 min. read 

](https://www.forgeway.com/learning/blog/understanding-the-diisocyanate-restrictions-2023)

[### Video: How to Comply with the New Diisocyanate Restrictions 2023

 March 14th, 2023|0 min. read 

](https://www.forgeway.com/learning/blog/how-to-comply-with-diisocyanate-restrictions-2023)

[### Understanding and Mitigating the Effects of Corrosion in Electric Vehicles

 February 13th, 2023|4 min. read 

](https://www.forgeway.com/learning/blog/corrosion-in-electric-vehicles)

```json
{
  "@context" : "https://schema.org",
  "@type" : "BlogPosting",
  "author" : {
    "@type" : "Person",
    "name" : "Migelo Buckley",
    "url" : "https://www.forgeway.com/learning/blog/author/migelo-buckley"
  },
  "dateModified" : "2024-07-18T11:13:35.956Z",
  "datePublished" : "2022-10-28T15:54:25.000Z",
  "headline" : "Advantages and disadvantages of welding as a joining method - Forgeway Ltd",
  "image" : [ "https://www.forgeway.com/hubfs/Welding-as-joining-method.jpg" ],
  "mainEntityOfPage" : {
    "@id" : "https://www.forgeway.com/learning/blog/advantages-and-disadvantages-of-welding",
    "@type" : "WebPage"
  },
  "publisher" : {
    "@type" : "Organization",
    "logo" : {
      "@type" : "ImageObject",
      "url" : "https://www.forgeway.com/hubfs/Picture1-1.jpg"
    },
    "name" : "Forgeway Ltd"
  }
}
```