Comparing Welding Processes: MIG, TIG, and Stick Welding

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.

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.

---