Cyclists can be categorized into two types: those who prefer welded frames and those who favor lugged frames. Welded frames actually meld two tubes together by using heat, while lugged frames fit straight tubes into lugs, or sleeved sockets similar to pipe fittings. The difference between lugged and welded frame construction requires understanding how the two construction techniques work and the inherent restrictions facing builders who employ each method.
Materials
To make an accurate comparison of welded vs. lugged frames, consider the materials that can be used in each construction process. All the major metals used for bike frames can be welded, including steel, aluminum and titanium; carbon fiber cannot be welded. Early carbon fiber frames were lugged by gluing carbon fiber tubes into steel sleeves, but frame makers moved on to more advanced processes for creating solid carbon fiber frames without resorting to steel lugs. Lugged metal frames utilize a brazing process that does not hold on aluminum or titanium but works on steel frames. To accurately compare welded and lugged frames, compare steel frames of similar quality since other materials do not offer suitable comparisons due to inherent limitations.
Strength
The process of welding creates a weak point in the frame at the spot of the weld. Lugged frame construction negates this because brazing does not weaken the steel on which the process was applied. Some makers can resort to butting the tubes, a process that makes the tubes thicker at stress points for strength and thinner in low-stress areas, which decreases weight. This process also can be used on lugged frames, but is an additional measure and not just to compensate for potential weak spots from welding. Frame makers also can gusset welded frames, which adds a piece of metal in a high-stress area, such as around the down tube and head tube weld. Gussets cannot be used on lugged frames, but the sleeve construction and brazing largely compensates for the lack of frame gussets.
Aesthetics
Visual appeal is a subjective discussion, but there are some inherent traits to welded and lugged frames that can sway potential buyers' opinions. Welded frames possess a level of inconsistent design around the weld, but higher-quality frame builders tend to have more consistency in their welds, making them more visually appealing. Lugged frames have a uniform appearance since the brazing occurs inside the lug. This design is classic and appeals to those favoring traditional frame styling, although the lug will always lay over the tube, which does not appeal to some who prefer a streamlined look. Meticulous frame builders also can use the frame's lugs to incorporate ornate styling and trademark design cues, which make for a bike with distinctive flavor.
Availability
Lugged frames were widely available until the 1980s, after which they fell out of favor. The two factors that led to this were the rise of cheap manufacturing in Asia, which lent itself to the cheaper and less technical welding process, and the fact that steel was overtaken in the marketplace by more exotic frame materials. Welded steel is common at entry-level and mid-level price points, but the extra care required for brazing lugs relegates the lugged frame to high-end, low-volume specialty builders as of 2011.
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