Welding plays a crucial role in numerous industries like construction, energy and power generation, automotive manufacture, fabrication and metalworking and more. It serves as the backbone of structural integrity and fabrication. Whether it’s joining metal components, creating intricate designs, or repairing machinery, welding cable provides the strength and durability needed for a wide range of applications.
However, selecting the right welding process is essential to ensure optimal results. Today, we have three commonly used welding techniques, namely MIG, TIG and stick welding. Once you get to know which process suits your specific project requirements, you can order welding cable accordingly and get started.
Let’s dive in and discover the finer details of these three welding techniques.
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A Closer Look at MIG, TIG and Stick Welding
There is no one-size-fits-all welding technique. Instead, we have different processes that come with their own pros and cons. Check out the meaning and advantages and disadvantages of the stick, MIG and TIG welding processes below.
Stick Welding
Also known as Shielded Metal Arc Welding (SMAW), stick welding is older than MIG and TIG welding. Here, an electric arc is used to create a weld joint between a coated electrode (or the ‘stick’) and the base metal. The electrode and the metal both melt to form the weld pool, while the flux coating keeps the weld pool safe from external contaminants.
The upsides of stick welding:
- Can be used for various applications
- Can be used to weld a wide range of metals
- Can be performed outdoors
- Creates a solid weld even on rusty surfaces
- Does not require a separate shielding gas
- Relatively more affordable than other welding techniques
- Can be performed by beginners too
The downsides of stick welding:
- Does not produce neat welds
- Produces a lot of splatter and debris
- Requires a fair bit of cleaning after the process is completed
MIG welding
MIG welding, also known as Gas Metal Arc Welding (GMAW), uses a continuously fed consumable electrode wire to create an electric arc between the wire and the workpiece. The electrode is fed at a constant pre-selected speed using a spool gun. And as the wire melts, it forms a weld pool with the base metal. To protect the weld pool from atmospheric contamination, a shielding gas (typically argon) is used.
The upsides of MIG welding:
- Creates a strong and durable weld
- Weld produced is generally neat and requires little to no cleaning
- Quick process that saves time for the welder
- Can be used to weld thin metals
- High deposition rates that minimize wastage
- Suitable for a wide range of materials
- Minimal splatter and debris
- Offers good control over the weld pool
The downsides of MIG welding:
- Difficult to use outdoors due to the presence of shielding gas
- Varying wire and gas requirements according to the metals being welded
- Requires more expertise than stick welding
TIG welding
In TIG welding or Gas Tungsten Arc Welding (GTAW), a non-consumable tungsten electrode is used to produce an arc between the electrode and the workpiece. While the tungsten electrode creates the arc, a separate filler rod may be used to add material to the weld joint. You will have to feed this filler rod into the weld pool with one hand and operate the welding torch with the other. The heat input is regulated through a control pedal that you must operate using your foot, and the weld pool is protected by a shielding gas like argon.
The upsides of TIG welding:
- Offers precise control over the heat input
- Allows for high-quality welds
- Produces clean and aesthetic welds
- Creates strong welds of extremely high quality
- Can be used to weld a wide range of materials
- Does not require a flux coating or consumable filler material, reducing the chances of contamination
- Allows for welding of thin materials without distorting or warping them
The downsides of TIG welding:
- Requires a high level of skill and experience
- Lower deposition rate than MIG welding
- Requires more expensive equipment and consumables
MIG vs TIG vs stick welding: How do they compare
Now that you know the fundamentals of each type of welding technique, let’s take a closer look at how they stack up against one another in various aspects.
| Criteria | MIG Welding | TIG Welding | Stick Welding |
| Speed and efficiency | High welding speed and deposition rate | Moderate welding speed and deposition rate | Low welding speed and deposition rate |
| Weld quality | Moderately good weld quality | Exceptional weld quality | Low weld quality |
| Weld appearance | May have spatter and a rough finish | Clean and aesthetically pleasing | Generally rougher than the other two welds |
| Welding positions supported | Suitable for flat and horizontal welding | Suitable for all welding positions | Suitable for all welding positions |
| Versatility | Suitable for carbon steel, aluminum, stainless steel, copper, bronze, nickel and magnesium | Suitable for steel, chromoly, stainless steel, nickel alloys, aluminum, copper, magnesium, bronze, gold and brass | Suitable for steel, aluminum, iron, nickel and copper |
| Required skill level | Beginner to intermediate skill level | Intermediate to advanced skill level | Beginner to intermediate skill level |
| Training required | Relatively easier to learn | Requires more training and practice | Relatively easier to learn |
| Cost of equipment and materials needed | Moderate costs | Higher costs | Lower costs |
| Safety considerations | Moderate risk of spatter | Requires precise control and handling of tungsten electrode | Moderate risk of electric shocks and burns |
| Control over heat input | Less control over heat input | Precise control over heat input | Variable control over heat input |
Conclusion
To sum it up, MIG welding offers high speed and efficiency, making it suitable for various materials and positions, while TIG welding excels in precision and produces aesthetically pleasing welds. Stick welding, on the other hand, is a versatile and cost-effective option for different welding positions.
This comparison of MIG, TIG, and stick welding processes should give you greater clarity on the unique characteristics and applications of each technique. The choice of the welding process for your project depends on several factors like the materials being welded, the desired weld quality and your skill level.
