Comparing MIG, TIG or Rod Welding – Which Is Best?

Mastering the art and science of welding can take quite a while. First, welders must develop technical skills in the craft itself. Next, he or she must also understand the limitations of material type, size, location, power supply, budget, and more. In the end, making metal is practical, satisfying, and (possibly) profitable. When starting out, the first question we hear is usually: compare MIG, TIG or Stick welding – which is best?

The short answer is – it depends. We will introduce you to the key aspects of MIG, TIG and Stick welding to help you understand the various conditions under which each process can be chosen. We also address the pros and cons of each.

Welding: it's a gas

All welding processes use electrodes, filler rods and shielding gas to create a temporary atmosphere conducive to a strong weld. But welding processes differ in terms of electrode consumption, filler material and source, and gas (and its delivery) in the welding zone. In short – there are many ways to soften it and refill it with high current arcing metal.

Stick welding is a basic process. It's also relatively cheap and easy to master. This process forms the starting point for many novice or amateur welders to learn the welding process.

We call stick welding "beginner" because the welder only needs to select the proper electrode and amperage. Every welding process requires shielding gas. In the case of stick welding or SMAW processes, consumable electrode rods provide this. The rod is coated with flux and when ignited by the arc, a shielding gas is produced. The electrodes then become molten metal that hardens into beads.

You can do a lot with stick welding – especially with a little practice. Stick welding is also suitable for contaminated or dirty materials (choose the correct electrode). You can also use this procedure for AC and DC power supplies. However, it's messy. Stick welding produces fumes, spatter and dross that take some time and effort to clean up.

We have also found that stick welding is not the best choice for very thin or very thick material or any type of aluminum. The best illustrations we found were from the IOC website:

MIG is a bit more complicated because the welder not only chooses the electrode and amperage, but also the voltage, wire speed and shielding gas. The MIG welding process also becomes more expensive than stick welding because you're delivering the shielding gas from a tank. These typically use a 75/25 argon/carbon dioxide mixture. The consumable electrode is also fed from a spool located inside most welders.

Managing wire, wire feed speed, gas, amperage and voltage seems like a lot. In the end, practice and experience can help you speed up producing some professional-looking welds with the MIG welding process.

Those new to welding can actually master DC powered MIG welding in a relatively short amount of time. The process produces virtually none of the fume, slag, and spatter levels of stick welding. That means less cleanup. When comparing MIG, TIG and Stick welding, cleanup is definitely in the equation.

Welders can also take advantage of the fast travel speed of the MIG torch to work quickly. MIG is also suitable for thinner materials. However, with MIG welding your material must be much cleaner than with Stick welding. Of course, we always recommend using clean materials – don't be lazy!

MIG is difficult to use outdoors because the wind can blow away the shielding gas, which can cause damage to the weld. For this reason, it is sometimes appropriate to use a flux-cored wire electrode on the spool of the MIG. This is similar to a flux electrode in stick welding. In this way, welders can ditch the gas tank and rely on flux to protect the welding process.

TIG or Tungsten Inert Gas aka Gas Tungsten Welding (GTAW)

TIG welding has the most variables, requires the most skill, and is by far the most expensive of all welding processes. We have also found it to be the most versatile welding process due to its ability to weld most metal thicknesses and types. This includes aluminum, making it suitable for a lot of automotive work. It is also used in art and any welds where the finished result will be very noticeable. This has to do with TIG welding producing the cleanest, most aesthetically pleasing overall welds.

TIG welding uses AC or DC power and does not consume its electrodes. It offers the welder maximum control as one hand holds the electrode, the other holds the filler rod and the foot pedal adjusts the amperage. Of course, this requires more coordination than any other welding process.

If you're driving a stick, you should be doing just fine!

When TIG welding you can also reduce the current to very low levels to prevent porosity in the material. However, this is a slower process, and the material must be very clean. TIG also works particularly well on aluminum – something that's either not possible, or at least much more difficult, with other welding processes.

Comparing MIG, TIG and Hand Welding: Charts!

We can summarize most of the basic details and characteristics of MIG, TIG or stick welding in this helpful diagram:

in conclusion

Our comparison of MIG, TIG and Stick welding is not intended to arbitrarily steer you in a particular direction. Instead, we want to help you understand the differences in cost, materials, and required skill levels. It also helps to understand the concept of shielding gases – especially with regard to how they fail in outdoor wind.

Our "favorite" welding has always leaned towards TIG welding. For those who really master the process, it seems like a real art form. Still, MIG welding has become surprisingly accessible—even for amateurs looking to get started.

For those interested in becoming a welder, you want to learn all three core processes. You also want to be extremely skilled in every aspect. The best welders move from one process to another when the job calls for it. Brace yourself, all your welds will look clean whether you're using MIG, TIG or stick welding.

Now, it's time to get to work. Happy welding!