Have you ever wondered what the differences are between MIG vs. TIG vs. stick welding? Each has its strengths, but picking the wrong one for your project can lead to wasted time and materials.

MIG (metal inert gas), TIG (tungsten inert gas), and stick welding involve joining metals through heating and melting, but their techniques differ. MIG uses wire and gas to create a fast, inexpensive weld. TIG is versatile but slower, using a non-melting tungsten electrode and gas to weld nearly any material. Stick welding works well for steel and thicker items, but requires more skill as the electrode is consumed in the arc.

The ideal welding process depends on your materials, budget, and skill level. Understanding the differences between these popular types of welding will help you choose what’s right for each project. 

What is MIG Welding

MIG welding, also known as gas metal arc welding (GMAW), involves using an electric current to create an arc between the continuously fed filler wire and the material being welded. This arc melts both the filler wire and base material. As they melt, they mix together and solidify into a strong weld. 

The process uses an inert gas, usually carbon dioxide or argon, to shield the welding area from oxygen and nitrogen in the air. It prevents the molten weld from reacting with these gasses and forming defects.

Welders use a welding gun that feeds the wire at a steady speed. Inside, the wire is heated by the electric current, so it melts off as it’s fed through. The gun also blows out the shielding gas as the welder moves it along. All the welder has to do is hold the gun close to the metal and it lays down the weld automatically with a “point and shoot” motion.

MIG is a fast and easy welding method for many applications. It works great on lots of materials, like steel and aluminum. It produces clean looking welding because of having no slag, unlike TIG and stick welding. The method is a top choice for workshops, fabrication shops, and DIY projects alike

Pros

• Easy to learn and use
• Fast welding speed
• Produces strong, high quality welds
• Can weld many metal types, including steel and aluminum
• No messy slag like other welding methods
• Equipment is relatively inexpensive

Cons

• Requires shielding gas, so not suitable for outdoor use
• Welds are more exposed to contamination
• Settings need adjusting for different material thicknesses and types
• More spatter/splatter than TIG welding
• Higher startup costs than stick welding

Tig Welding

TIG welding, also called gas tungsten arc welding (GTAW), is a type of welding that produces some of the highest quality welds. It uses a non-melting tungsten electrode to create an arc between the electrode and the welding metals. 

An inert gas is used to shield the welding area from oxygen in the air. This gas is usually argon but may contain a small amount of helium.

During the welding operation, the welder uses a tungsten electrode torch. They precisely feed a filler metal rod into the weld area, while controlling the electric current with a foot pedal. So, they have full control over how hot the welding arc will be.

The gas shielding and manual control of the filler rod mean that TIG welds can be very clean and precise. It is often used when appearance is important, like for artwork or automotive trim pieces. The welds are also very strong since contaminants are kept out of the weld area. It makes TIG great for welding thinner materials in advanced precision machining or joining different types of metals. 

However, TIG welding does take some practice to get good at, unlike MIG and stick welding. It tends to be slower than other welding methods since the adding of the filler rod is manual. Specialized welding equipment is also required. But for applications where quality is paramount, TIG welding remains the gold standard. 

Pros

• Produces very high quality, strong welds
• Good for welding of thin materials 
• Used in precision machine shops
• Can join dissimilar metals
• Can be used for artistic/ornamental projects
• Welders can control the heat input and weld appearance

Cons

• Requires expensive specialized equipment
• Takes more time to set up and perform than other welding methods
• Slower welding deposition rate than other processes
• Not suitable for thicker materials requiring high heat input
• Requires welders to be highly skilled

Stick Welding

Stick welding, also known as shielded metal arc welding (SMAW), is a popular and practical welding method used by both professionals and hobbyists. In this process, a flux-coated electrode rod is connected to a power source to create an electric arc. The arc melts both the electrode and the welding metal pieces, joining them together into a strong bond.

As the electrode burns away, more metal from the rod flows into the weld pool to join the pieces. The flux coating on the rod protects the hot weld from impurities in the air. Once cooled, the flux forms a protective slag cover over the weld.

Stick welding is a great choice for beginners because it is simple, affordable, and gets the job done. While the finished welds may not look perfect, it allows quick repairs that hold strongly. The equipment is inexpensive compared to other welding methods. All you need is a basic electric welding machine and replaceable electrode rods.

The technique does have some trade offs compared to other welding processes. Cleaning slag off welds takes extra time. Frequent electrode changes and more splatter also slow down productivity. 

Compared to MIG and TIG welding, this technique is by far the most inexpensive. It’s also the most practical option for its flexibility outdoors or on dirty metals. 

Pros

• Inexpensive welding equipment
• Can be used anywhere with a power source
• Works well for outdoor settings
• Tolerates rust and imperfect surfaces better than other methods
• Welds variety of metals including steel, iron, aluminum

Cons

• Finished welds are not as clean as other methods
• More splatter and spatter to grind away
• Slag requires chipping between passes
• Slower overall than other welding processes
• Exposure to UV light from electric arc

MIG vs. TIG vs. Stick Welding Comparison Table

For your better understanding of MIG vs. TIG vs. stick welding differences and similarities, we’ve created a comparison table. 

All these processes use a closed electrical circuit. Their technique involves using electric arc and electrical resistance to melt the materials and create the welding joints. However, there are still differences that make these methods special in their own way.

This table explains what materials you can weld, costs, cleanliness, and more. So, whether you’re building a robot or fixing a broken bike, this chart will help you pick the perfect welding technique for your project!

MIG vs. TIG vs. Stick Welding Comparison

Conclusion

The comparison of MIG vs. TIG vs. stick welding techniques makes it clear that they all have their strong and weak points. MIG is fast, easy to learn, and good for common fabrication. TIG is great for high-quality welds on thinner materials but requires more skill. Stick welding is affordable, portable, and works well outdoors, but the welds are less clean. Choosing the right method depends on your project, budget, and experience level.

Need welding done right? Give Zintilon a try. Our experts can provide sheet metal welding and precision machining services for a variety of your production needs. Get a free quote!

————————————