GITNUXREPORT 2025

Welding Statistics

Global welding market grows steadily, driven by automation, safety, and innovation.

Jannik Linder

Co-Founder of Gitnux, specialized in content and tech since 2016.

First published: April 29, 2025

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Statistic 1

The average lifespan of a professionally welded aluminum boat hull is about 25 years

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Ultrasonic welding is commonly used in the automotive industry to join plastics and thin metals

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Steel accounts for approximately 70% of all welded materials globally

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Gas tungsten arc welding (GTAW) or TIG welding is favored for aerospace applications due to its precision

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The average cost of a professional welding training course ranges from $1,000 to $4,000, depending on the duration and specialization

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Thermal spray welding is commonly used in repair applications for turbine blades and industrial machinery

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The penetration of arc welding into automotive manufacturing accounts for over 40% of all industrial welding activities

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The average weld deposit hardness for high-carbon steels can reach over 55 HRC, contributing to wear resistance

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Laser welding is used in the production of medical devices due to its precision and cleanliness

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In offshore oil and gas industry, subsea welding accounts for around 15% of all welding activities, critical for structural integrity

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The global welding market was valued at approximately $30 billion in 2020

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It is projected to grow at a CAGR of around 5.4% from 2021 to 2028

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The global demand for welding consumables is expected to reach over $20 billion by 2025

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The process of shielded metal arc welding (SMAW) was developed during the 1920s and remains widely used today

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Non-destructive testing (NDT) techniques are used in over 80% of welding inspections worldwide

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The use of automated welding robots has boosted productivity by up to 25%

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The global demand for aluminum welding is projected to grow at a CAGR of 4.8% through 2027

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The use of corrosion-resistant coatings in welds can extend the lifespan of structures by up to 50%

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The adoption of Internet of Things (IoT) sensors in welding equipment is increasing, with over 35% of new machines equipped with smart technology in 2023

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The average annual maintenance cost for industrial welding equipment can reach up to $15,000 depending on usage

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Advanced simulation software for welding process optimization is used by over 60% of large manufacturing firms

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MIG welding is the most commonly used welding process in the construction industry, accounting for over 45% of all welding activities

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The average lifetime of a welding power source in a manufacturing plant is approximately 10-15 years with proper maintenance

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The global market for portable welding equipment is dominated by stainless steel and aluminum applications, projected to grow significantly in upcoming years

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The use of magnetic pulse welding technique in manufacturing is growing due to its ability to join dissimilar metals rapidly

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The adoption of 3D printing technology in welding is expected to grow at a CAGR of 11% through 2030

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The welding helmet market size was valued at approximately $500 million in 2020 and is expected to grow steadily

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The global portable welding machine market is projected to reach $3 billion by 2025, growing at a rate of 6% annually

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The global market for welding helmets was valued at approximately $600 million in 2020, with expected growth driven by safety regulations

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The global market for welding consumables is expected to reach $23 billion by 2027, growing at a CAGR of 4.2%

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The use of robotic welding accounts for approximately 20% of all industrial welding processes in 2023

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The welding industry contributes approximately $250 billion annually to the global economy

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The use of fiber laser welding has grown by over 15% annually since 2015

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In 2022, the leading country in total welding equipment exports was China, with exports valued at over $2 billion

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The global demand for stainless steel welding increased by approximately 3% annually between 2015 and 2020

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The use of welding automation in shipbuilding can reduce production time by up to 30%

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The adoption of environmentally friendly welding practices, such as low-emission flux coatings, is increasing and reduces pollutant emissions by over 20%

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The growth of additive manufacturing has led to increased use of wire and arc additive manufacturing (WAAM), a form of welding, with a projected market growth of 7% annually through 2025

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The most common welding process is Gas Metal Arc Welding (GMAW), also known as MIG welding

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Electron beam welding can achieve weld depths of up to 10 inches in a single pass

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In shipbuilding, precision welding is crucial, with tolerance levels often less than 1 millimeter

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The introduction of new welding techniques like laser hybrid welding reduces energy consumption by up to 30%

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The development of hybrid welding processes combining laser and arc welding technologies enhances efficiency and reduces costs

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Around 90% of welders in the United States are male

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The median annual wage for welders in the US was approximately $44,190 in May 2020

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Exposures to welding fumes can increase the risk of lung cancer by up to 30%

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Over 50% of welding injuries involve burns or eye injuries

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Approximately 65% of welders report working overtime frequently, which increases safety risks

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The average age of a professional welder is around 45 years old, indicating an aging workforce

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The most common safety equipment used by welders includes gloves, safety glasses, and welding helmets

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The Occupational Safety and Health Administration (OSHA) has issued over 1,000 citations annually related to welding safety violations in recent years

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Approximately 25% of welders experience occupational asthma due to fumes and dust

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Ultraviolet radiation from welding arcs can cause photokeratitis, also known as "arc eye," in about 10% of welders without protective gear

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According to surveys, over 70% of welders have experienced some form of work-related injury or illness at some point in their careers

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Welding-related fires account for approximately 4% of industrial fires annually, emphasizing safety importance

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Technological advances in welding safety, such as automated shut-off systems, have reduced accidents on job sites by approximately 25%

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Key Highlights

The global welding market was valued at approximately $30 billion in 2020
It is projected to grow at a CAGR of around 5.4% from 2021 to 2028
Around 90% of welders in the United States are male
The median annual wage for welders in the US was approximately $44,190 in May 2020
Exposures to welding fumes can increase the risk of lung cancer by up to 30%
The most common welding process is Gas Metal Arc Welding (GMAW), also known as MIG welding
Over 50% of welding injuries involve burns or eye injuries
The global demand for welding consumables is expected to reach over $20 billion by 2025
Electron beam welding can achieve weld depths of up to 10 inches in a single pass
The average lifespan of a professionally welded aluminum boat hull is about 25 years
The use of robotic welding accounts for approximately 20% of all industrial welding processes in 2023
The process of shielded metal arc welding (SMAW) was developed during the 1920s and remains widely used today
Ultrasonic welding is commonly used in the automotive industry to join plastics and thin metals

Welding, a cornerstone of modern industry with a market valued at $30 billion in 2020 and poised for continued growth, combines age-old techniques with cutting-edge innovations—yet it also presents significant safety challenges and evolving workforce dynamics.

Industry Applications and Sectors

The average lifespan of a professionally welded aluminum boat hull is about 25 years
Ultrasonic welding is commonly used in the automotive industry to join plastics and thin metals
Steel accounts for approximately 70% of all welded materials globally
Gas tungsten arc welding (GTAW) or TIG welding is favored for aerospace applications due to its precision
The average cost of a professional welding training course ranges from $1,000 to $4,000, depending on the duration and specialization
Thermal spray welding is commonly used in repair applications for turbine blades and industrial machinery
The penetration of arc welding into automotive manufacturing accounts for over 40% of all industrial welding activities
The average weld deposit hardness for high-carbon steels can reach over 55 HRC, contributing to wear resistance
Laser welding is used in the production of medical devices due to its precision and cleanliness
In offshore oil and gas industry, subsea welding accounts for around 15% of all welding activities, critical for structural integrity

Industry Applications and Sectors Interpretation

While steel dominates the global welding industry at 70%, whether you're building an aluminum boat destined to sail for 25 years or repairing turbines with thermal spray, honing a weld—like investing in a $1,000 course or mastering laser precision—ensures safety, durability, and a splash of ingenuity across industries from aerospace to oil rigs.

Industry Growth and Market Size

The global welding market was valued at approximately $30 billion in 2020
It is projected to grow at a CAGR of around 5.4% from 2021 to 2028
The global demand for welding consumables is expected to reach over $20 billion by 2025
The process of shielded metal arc welding (SMAW) was developed during the 1920s and remains widely used today
Non-destructive testing (NDT) techniques are used in over 80% of welding inspections worldwide
The use of automated welding robots has boosted productivity by up to 25%
The global demand for aluminum welding is projected to grow at a CAGR of 4.8% through 2027
The use of corrosion-resistant coatings in welds can extend the lifespan of structures by up to 50%
The adoption of Internet of Things (IoT) sensors in welding equipment is increasing, with over 35% of new machines equipped with smart technology in 2023
The average annual maintenance cost for industrial welding equipment can reach up to $15,000 depending on usage
Advanced simulation software for welding process optimization is used by over 60% of large manufacturing firms
MIG welding is the most commonly used welding process in the construction industry, accounting for over 45% of all welding activities
The average lifetime of a welding power source in a manufacturing plant is approximately 10-15 years with proper maintenance
The global market for portable welding equipment is dominated by stainless steel and aluminum applications, projected to grow significantly in upcoming years
The use of magnetic pulse welding technique in manufacturing is growing due to its ability to join dissimilar metals rapidly

Industry Growth and Market Size Interpretation

As the $30 billion global welding industry surges with a 5.4% CAGR fueled by innovation—from robotic automation to IoT smart sensors—and a steadfast devotion to tried-and-true methods like SMAW, it’s clear that whether extending lifespans with corrosion-resistant coatings or welding dissimilar metals via magnetic pulse, the craft remains both a cornerstone of modern construction and a shining example of how precision, technology, and history weld a future of stronger, smarter structures.

Industry Trends and Innovations

The adoption of 3D printing technology in welding is expected to grow at a CAGR of 11% through 2030

Industry Trends and Innovations Interpretation

With an anticipated 11% CAGR through 2030, the welding industry's embrace of 3D printing signifies not just a technological upgrade, but a blueprint for reshaping manufacturing's future—proof that even sparks can fly for innovation.

Market Size

The welding helmet market size was valued at approximately $500 million in 2020 and is expected to grow steadily
The global portable welding machine market is projected to reach $3 billion by 2025, growing at a rate of 6% annually
The global market for welding helmets was valued at approximately $600 million in 2020, with expected growth driven by safety regulations

Market Size Interpretation

The welding industry’s robust safety gear and portable machinery markets, collectively worth billions and fueled by strict regulations and steady growth, underscore a powerful spark igniting both innovation and the importance of protecting what’s being built.

Market Size and Market Size

The global market for welding consumables is expected to reach $23 billion by 2027, growing at a CAGR of 4.2%

Market Size and Market Size Interpretation

With the welding consumables market projected to hit $23 billion by 2027 at a steady 4.2% growth rate, it’s clear that industries are sparking up their investments, forging ahead with confidence in their — quite literal — binding power.

Market Trends and Innovations

The use of robotic welding accounts for approximately 20% of all industrial welding processes in 2023
The welding industry contributes approximately $250 billion annually to the global economy
The use of fiber laser welding has grown by over 15% annually since 2015
In 2022, the leading country in total welding equipment exports was China, with exports valued at over $2 billion
The global demand for stainless steel welding increased by approximately 3% annually between 2015 and 2020
The use of welding automation in shipbuilding can reduce production time by up to 30%
The adoption of environmentally friendly welding practices, such as low-emission flux coatings, is increasing and reduces pollutant emissions by over 20%
The growth of additive manufacturing has led to increased use of wire and arc additive manufacturing (WAAM), a form of welding, with a projected market growth of 7% annually through 2025

Market Trends and Innovations Interpretation

As welding technology advances—from robotics and fiber lasers to eco-friendly practices and additive manufacturing—it's clear that the industry, which injects $250 billion into the global economy, is not just forging metal but also shaping a more efficient, sustainable, and economically vital future.

Welding Techniques and Technologies

The most common welding process is Gas Metal Arc Welding (GMAW), also known as MIG welding
Electron beam welding can achieve weld depths of up to 10 inches in a single pass
In shipbuilding, precision welding is crucial, with tolerance levels often less than 1 millimeter
The introduction of new welding techniques like laser hybrid welding reduces energy consumption by up to 30%
The development of hybrid welding processes combining laser and arc welding technologies enhances efficiency and reduces costs

Welding Techniques and Technologies Interpretation

While MIG welding dominates the industry and laser hybrid techniques promise greener and more cost-effective solutions, the relentless pursuit of precision—down to less than a millimeter—reminds us that in welding, as in life, the smallest details make the biggest difference.

Workforce Demographics and Safety

Around 90% of welders in the United States are male
The median annual wage for welders in the US was approximately $44,190 in May 2020
Exposures to welding fumes can increase the risk of lung cancer by up to 30%
Over 50% of welding injuries involve burns or eye injuries
Approximately 65% of welders report working overtime frequently, which increases safety risks
The average age of a professional welder is around 45 years old, indicating an aging workforce
The most common safety equipment used by welders includes gloves, safety glasses, and welding helmets
The Occupational Safety and Health Administration (OSHA) has issued over 1,000 citations annually related to welding safety violations in recent years
Approximately 25% of welders experience occupational asthma due to fumes and dust
Ultraviolet radiation from welding arcs can cause photokeratitis, also known as "arc eye," in about 10% of welders without protective gear
According to surveys, over 70% of welders have experienced some form of work-related injury or illness at some point in their careers
Welding-related fires account for approximately 4% of industrial fires annually, emphasizing safety importance
Technological advances in welding safety, such as automated shut-off systems, have reduced accidents on job sites by approximately 25%

Workforce Demographics and Safety Interpretation

Despite a predominantly male workforce and increasing safety technology, the aging median age, frequent overtime, and persistent hazards—from fumes to fires—highlight that welding remains a high-stakes trade where vigilance and safety compliance are vital to prevent costly injuries and health risks.