Key Takeaways
- More than 320,000 new welding professionals will be needed by 2029, according to the American Welding Society (AWS).
- Many welding companies are investing in artificial intelligence (AI) and automation to improve efficiency and help address gaps in the workforce.
- AI is already being used for real-time monitoring, defect detection, predictive maintenance, and training support.
Welding is a hands-on, skill-driven trade — but the tools that welders use are getting smarter. As experienced welders retire and demand for new talent arises, the industry is evolving fast. That’s where artificial intelligence (AI) comes in.
The American Welding Society (AWS) states that more than 20% of welders are nearing retirement — that turnover means more than 320,000 new welding professionals will be needed by 2029. But as the workforce replenishes with incoming skilled talent, AI is helping them work more efficiently, not replacing them. AI helps catch issues earlier, and produces more consistent results. From real-time monitoring to advanced training tools, these technologies are starting to reshape what a typical day on the job looks like.
If you’re thinking about a future in welding, understanding how AI fits into the field isn’t just helpful — it’s quickly becoming part of the job.
How Can AI Be Used in Welding?
Though adoption is still in the early stages, AI already shows up in welding in several ways, particularly in industrial and automated environments. Some common applications of AI in welding include the following:
Real-time weld monitoring: AI-assisted systems can track welding conditions while work is happening and flag abnormalities before they become bigger problems. These tools analyze welding parameters and help operators make corrections in real time.
Inspection and defect detection: AI can help identify potential defects that welders might not catch right away. In some cases, this involves computer vision systems that analyze elements such as the weld pool, wire behavior, or spatter during the welding process.
Predictive maintenance: One of AI’s most practical uses in welding — and manufacturing more broadly — is supporting proactive equipment maintenance. AI can monitor wear and performance, helping shops identify when parts need attention before they lead to downtime or quality issues.
Training support: AI is also being used in welding training tools and simulators. These tools can evaluate hand motion and arc behavior, then provide targeted feedback to help students and apprentices improve.
Benefits of Welding AI and Automation
As AI and automation become more common in welding, their value extends beyond speed and efficiency. They can also support more consistent — and sometimes higher quality — results, which is why so many organizations are investing in these complementary technologies. Mobility Foresights estimates that the global AI-based welding market will grow by 250% over the next several years, increasing from $650 million in 2024 to $2.3 billion by 2031.
Below are some of the most notable benefits of using AI in welding.
More Consistent Weld Quality
One of AI’s biggest advantages in welding is consistency. Automated and AI-assisted systems can monitor variables over long periods, helping minimize variations that can affect weld quality.
Consistency and quality, along with greater efficiency, are why many fabricators continue investing in automated arc welding.
Early Problem Detection
In more traditional workflows, some weld issues aren’t caught until inspection or until a defect affects production. AI can shorten that gap by identifying abnormalities earlier.
Early detection can help operators respond faster, which may reduce disruptions and prevent minor problems from escalating. As AI-assisted welding tools continue to improve, the ability to catch issues earlier may become even more valuable in busy manufacturing settings.
Greater Productivity
Automation is often associated with higher productivity, and AI can strengthen that advantage. By helping systems adapt to changing conditions and maintain performance more effectively, AI can support faster, more efficient production.
In some advanced applications, AI-assisted systems may also reduce operator workload, helping workers oversee equipment and make corrections.
Key AI Skills for Welding Professionals
You don’t need to be a programmer to succeed in modern welding — but as AI and automation become more common, a few key skills can set you apart.
Comfort with digital tools: Today’s welding environments often include software, monitoring systems, and connected equipment. Being confident using these tools makes day-to-day work smoother.
Interpret AI insights: AI can flag issues or suggest adjustments, but it’s up to you to understand the feedback and take action.
Basic automation awareness: Even if you start with manual welding, knowing how automated and robotic systems fit into the workflow is a big advantage.
At the same time, strong fundamentals still matter. The better you understand core welding techniques, the easier it is to work with — and benefit from — new technology.
What AI Means for the Future of Welding
AI is changing the tools that welding professionals use and reshaping what modern welding can look like. From weld monitoring to predictive maintenance and training support, AI is playing a larger role in how the industry approaches quality and efficiency.
If you’re considering a future in welding, explore the Welding Training programs at Fortis. With programs in Alabama, Georgia, Ohio, and Texas, we strive to make it more convenient and accessible for aspiring welders to achieve their professional goals. Our programs combine classroom instruction with hands-on training to help you develop the practical skills you need to excel in this evolving field.
Recommended Readings
Preparing for a Career in Welding
How Long Does It Take to Become a Welder?
4 Facts About Welding
Sources:
American Welding Society, Certified Robotic Arc Welding (CRAW) Program
American Welding Society, Implementing AI in Welding
American Welding Society, Welding Workforce Data
American Welding Society, Why Fabricators Continue to Choose Automated Arc Welding
IBM, IBM and AWS Partnering to Transform Industrial Welding With AI and Machine Learning
Mitsubishi Heavy Industries Technical Review, “Development of Welding Technology With Artificial Intelligence”
Mobility Foresights, Global AI Based Welding Market Size, Share and Forecasts 2031
National Science Foundation, “Welding Instructors’ Perspectives on Using AI Technology in Welding Training”
Novarc Technologies, Welding Automation and AI Are Changing the Industry
Ocean Engineering, “Advancements in Control Systems and Integration of Artificial Intelligence in Welding Robots: A Review”