Factors to Determine What Aircraft Welding to Use

In the welding industry, there are many different types of welding. The type of welding you use depends on the material you are welding and the purpose of the welded part. 

Get your aircraft in tip-top shape at all times with the Knisley Welding Aircraft Exhaust System. Contact us at or call us at (800) 522-6990 (toll-free)!

In this article, we will go over some factors to consider when choosing your aviation welding method to ensure you get the best results possible.

Material Type

One of the first things you should determine when choosing an aviation welding process is what type of metal you will use. The two main types of metals used in the construction of aircraft parts are steel and aluminum. 


Steel can be found in just about every component of an aircraft, from the fuselage to landing gear components. On the other hand, aluminum is usually reserved for smaller parts such as fuel tanks or engine mounts.


When considering what method to use for your project, it’s important to keep in mind that some materials require special equipment designed specifically for their particular needs. 


For example, resistance welding requires an electric arc torch because it heats material using electricity instead of friction. However, this would not work on aluminum because this type of torch does not generate enough heat for welding purposes (and could damage your part if used on it). 

Filler Material Characteristics

The filler material is used to fill the gap between two parts that need to be welded together. It should be a good electrical and thermal conductor if you want it to conduct heat evenly throughout both pieces of metal being welded together. 


It should also be strong but not brittle. This ensures that no damage will occur while welding and after completing the weld. Additionally, it must resist corrosion or rusting over time so that your final product will last long into its lifetime without requiring repairs or maintenance.

Aircraft Part’s Surface

This is one of the biggest factors determining the types of welding used in aircraft. Here are some things to keep in mind:

  • Cleanliness: The cleaner your surface is, the better your results will be. It includes removing oils from metal surfaces before starting a job or using an etching agent before welding on a part coated with paint or primer.
  • Hardness: Using a low-output power source is recommended if you’re working on parts made of soft metals (like mild steel). High outputs can damage softer materials like aluminum or nickel-based alloys without proper shielding gas protection (see below).
  • Smoothness:  A smooth finish looks better than an uneven one. However, it also reduces friction between different surfaces. This is because they can rub against each other as things don’t always stay put as they should!


Key Takeaway

To determine what types of welding are used in aircraft, you first need to consider the purpose of your welded part. Welds are typically used for strength and rigidity, aesthetics, weight savings, corrosion resistance, or a combination of these factors.


There is no one-size-fits-all solution when it comes to choosing an ideal process. Instead, it depends on several variables, including what material will be visible and how much ductility you need. 


At Knisley Welding Aircraft Exhaust System, we have a team of experts who use advanced techniques and tools to weld aircraft exhaust systems that are strong and durable. Contact us at or call us at (800) 522-6990 (toll-free)!