No matter which type of welding is more popular, TIG or MIG, both have their benefits and vulnerabilities. MIG vs. TIG welding is very different from one another in a lot of ways.
It all depends on the location of the weld and its rigidity. To know more about both welding techniques, you need to read this article.
MIG & TIG welding are two types of welding that you should know about. These two methods of welding are commonly used because of their versatility, effectiveness, and precision.
In this article, I will outline the differences, similarities, and other important things between MIG and TIG welding.
MIG Vs. TIG Welding
MIG welding is an arc welding process that uses a continuous wire electrode and a consumable electrode that is heated by an electric arc. TIG welding is also an arc welding process, but it uses a non-consumable or “electrode stick” made of tungsten that is fed into the weld puddle from a gas-shielded electrode holder.
If you want a fast, efficient, and easy-to-learn welding technique, I recommend going for MIG. On the other hand, TIG produces a cleaner weld with less spatter.
Both of these welding techniques are suitable for welding projects according to project requirements. It is better for you to go for a technique suitable for your welding project.
In the remaining article, I will tell you about both welding techniques’ applications so that you can easily know which one best suits your needs.
What is the Process of MIG Welding?
MIG welding is a process used to join materials together through the use of a welding electrode and flux. The acronym MIG stands for Metal Inert Gas, which refers to the shielding gas that is used during welding.
When the welding electrode melts, it creates a pool of molten metal that fuses with the materials being joined together.
MIG welding is one of the most commonly used methods of joining metals due to its simplicity and ability to use different types of filler materials.
The process begins by using an inert gas such as argon or helium as a shielding gas in order to protect the weld from contamination.
The wire feeder ensures that enough filler metal is applied to ensure that there is enough weld for proper bonding without causing excessive buildup on the surface of where you are working.
What is the Process of TIG Welding?
The TIG (tungsten inert gas) welding process uses an electric arc between a consumable tungsten electrode and the weld pool to melt the base metal. It is semi-automatic or automatic, depending on the machine being used.
The TIG process uses a non-consumable wire electrode, which can be made of either pure tungsten or nickel-chromium alloy.
The wire electrode is held in place by an externally supplied filler rod, which also serves as an electrical contact. The filler rod melts and flows around the weld puddle, shielding it from the atmosphere during welding.
A constant current power supply provides high-frequency alternating current to strike an arc at the end of the tungsten electrode when it is touched to the workpiece surface.
This arc heats and melts the base metal, causing it to flow into its surrounding slag pool or protective covering layer of molten flux.
When welding large sections of different metals together, a separate filler rod must be used for each type of metal being joined together, one for steel and another for aluminum, for example, or else they will not fuse properly together during cooling after heating them with an electric arc during welding.
Which One Costs Higher: MIG or TIG Welding?
If you’re looking to get into welding, it’s easy to get overwhelmed by all the different options.
But don’t freak out! It’s totally okay to start out with one type of welding and then work your way up to another. You don’t have to know everything right away.
So which one does cost more: MIG or TIG? You might be surprised!
MIG (metal inert gas) welding is actually the cheapest option if you’re just getting started in welding. This is because MIG welders are much cheaper than TIG welders, and they can be used for multiple types of metals, not just steel, as TIG welders do best.
TIG (tungsten inert gas) welding is a little trickier than MIG welding because it requires more skill and practice to master. But once you get the hang of it, you’ll be able to work on all kinds of materials like stainless steel, aluminum, and even precious metals like gold or platinum!
I performed both types of welding, and according to my experience, MIG welding is much easier & cheaper as compared to TIG welding. If you are a beginner & stick between MIG or TIG welding, then I suggest going for MIG.
Similarities Between MIG & TIG Welding
MIG and TIG welding are both methods of joining metals by using a wire to transfer the heat from your welding torch to the metal you’re working with.
Both MIG and TIG welding have their own pros and cons, but they both have a lot in common.
For example, one of the main similarities between MIG and TIG welding is that they both require a shielding gas to protect your weld joint from oxygen while you’re working on it.
Another similarity between MIG and TIG welding is that they both use filler materials (e.g., rods) that melt when they come into contact with the heat from your torch.
However, each method has its own unique way of applying this filler material to the weld joint so that it melts smoothly at just the right time and not before or after!
Which Equipments are Required?
The equipment required for MIG/TIG welding is:
- Welding machine
- Welding wire feeder and spool gun
- The power source (generator or MIG/TIG welder)
- Torch or gun with tips and accessories
- Ground clamp or clamping system
- Tungsten electrode holder and tungsten electrode (if needed)
Major Differences
MIG and TIG welding are both methods of electrically perfecting steel. They use a wire feeder to apply a thin, continuous layer of metal to the weld joint.
However, there are some major differences between MIG and TIG welding. I am going to highlight some of the differences as follows:
1. Shielding Gas:
When it comes to MIG and TIG welding, the biggest difference is their shielding gas. Both MIG and TIG welders use shielding gas to protect the molten weld from oxygen and other elements in the air that would interfere with or prevent the formation of a quality weld.
The MIG process uses a mixture of argon and carbon dioxide to produce a continuous weld with a smooth surface finish.
For MIG welding, I recommend that you should use argon (75%) and CO2 (25%) for a better weld. If you use CO2 in more quantity, then you may face porosity and cracking issues. In the case of MIG welding aluminum, you should have to use pure 100% argon.
The TIG process uses an inert gas such as argon to shield the arc from oxygen in the air, resulting in an arc that produces little or no spatters.
It is best to avoid using the C02 & oxygen because the tungsten electrode is sensitive to using these gases. Argon is highly recommended use for TIG welding.
2. Gas Flow Rate:
The gas flow rate for MIG welding is 35 to 50 cubic feet per hour. The arc length is typically between 5/8 and 1 inch.
On the other hand, the gas flow rate for TIG welding is 15 to 25 cubic feet per hour. The arc length is typically between 1/8 and 3/8 of an inch long.
3. Speed:
The major difference between MIG and TIG welding is the speed at which they weld. In MIG welding, the wire is fed in a continuous stream into the weld puddle, and the operator controls the process by varying the amperage as needed.
In TIG welding, on the other hand, a single piece of filler metal is deposited at a time. This means that MIG welds tend to be faster than TIG welds.
TIG welds are also more difficult to learn because they require more operator skills than MIG welds do.
4. Strength:
The weld strength of a MIG or TIG weld is determined by several factors. The most important factor is the amount and size of the filler metal deposited during the welding process.
The type of metal you’re welding can also affect the strength of your weld. For instance, stainless steel and aluminum are more difficult to weld than other types of metals because they are more susceptible to thermal stress.
The thickness of the material being welded also affects how strong a weld is. Thinner materials tend to have weaker welds than thicker materials because they offer less supporting material for the heat-affected zone (HAZ).
5. Weld Beads:
All welds are not created equal. In fact, the aesthetic differences between MIG and TIG welds can be striking.
MIG welds tend to have a smoother, more fluid look than TIG welds. This is because MIG welding uses a wire feeder to deliver metal wire through the gun and down to the workpiece. The wire is melted and fused with the base material to form a bead of welded metal.
TIG welding, on the other hand, relies on an arc between an electrode held in one hand and the workpiece in order to create the weld puddle. The molten metal from this arc is what forms your finished weld bead.
This difference in process results in two very different aesthetics for your finished product: smooth and fluid for MIG or jagged and spiky for TIG.
6. Aluminum Welding:
Aluminum is the most difficult to weld. It requires a high heat setting and a very clean, almost oxygen-free environment. The aluminum reacts with the oxygen in the air and forms a hard coating on the surface of the metal.
This coating prevents it from being welded to other metals, so it must be cleaned off before welding can begin.
Aluminum is a common soft-welding metal that can be welded with either MIG or TIG welding.
MIG welding is typically used for thin aluminum parts, while TIG welding is usually used for aluminum parts that are thicker than 1/8 inch.
The reason why TIG welding is preferred over MIG welding when welding thicker aluminum parts is that the heat generated by MIG welding can cause the formation of hydrogen bubbles in the weld. This causes porosity and weakens the welded joint.
If you want to weld aluminum, then I recommend going for TIG with a foot pedal because it provides you with better results. MIG welding aluminum is also best, but it may create spatter issues. So, I advise that you should weld aluminum with proper care & precautions.
7. Stainless Steel Welding:
The best way to weld stainless steel is with a gasless wire feed system. When using this type of system, you can weld in all positions, including overhead, vertical, and horizontal.
The biggest downside of a gasless system is the cost, which can be as much as 15% higher than traditional MIG welding equipment. You’ll also need to use a shielding gas such as CO2 or argon/CO2 blends when welding stainless steel with a gasless system.
A TIG welder is the best tool for welding stainless steel because it allows you to precisely control the temperature of the arc and the heat input into the weld puddle.
This means that you can get better penetration into the base metal and produce more consistent results than MIG welding does on its own.
In which Conditions MIG Welding is Better?
MIG welding is a great option for many projects. However, there are some things you should know before jumping into your next MIG project.
Although MIG welding is much easier to learn than other types of welding, it does have a few quirks that can catch new welders off guard. Here are some situations in which MIG welding is the best choice:
| No. | Conditions | Explanation |
| 1. | For Thick Metals | If you need to weld thick metals, then MIG welding would be a good choice for you because it is much faster than other methods such as TIG (tungsten inert gas) welding. |
| 2. | For Beginners | MIG welding is the most common method used by hobbyists because it is relatively easy to learn how to use it correctly with minimal practice time required before you can begin creating your own projects. |
| 3. | For Large Projects | MIG welding is ideal for applications where there’s not enough room for other types of welding or for large projects that require multiple passes over greater distances. |
| 4. | For Construction | MIG can be used to weld in all positions. It is often used for overhead welding, which is common on construction sites because it allows you to weld in any position. |
| 5. | For Long Run | If you’re working on a long run of welds, MIG is probably your best bet. MIG can handle long runs more easily than TIG welding because it doesn’t require filler wire or additional shielding gas bottles. |
In which Conditions TIG Welding is Better?
| No. | Conditions | Explanation |
| 1. | For Non-Ferrous Metals | TIG is used for welding aluminum and other non-ferrous metals. It can be used to weld aluminum, magnesium, copper, and brass. |
| 2. | For Thin Sections | It is also used when there are thin sections or when you need to fill in holes or gaps that have been created by machine part removal processes. |
| 3. | For Fabrication & Repairs | The TIG process is commonly used for the fabrication and repair of components that require high mechanical properties, tight tolerances, and surface finishes. |
| 4. | For Experienced Welders | TIG requires more skill than MIG, and it may not be suitable for inexperienced welders who lack the necessary training and experience required by this process. |
| 5. | For Short Run | It is recommended to use for a short run as I have experienced TIG welding with a short-run welding project. |
Final Words!
As you’ve seen, MIG vs. TIG welding each has its advantages. MIG welding is generally easier to learn, while TIG welding delivers a better-finished product.
If you’re already familiar with one process, that’s important to keep in mind, and practice makes perfect. No matter which weld type you choose, the more practice you get, the better your technique will be.
With any luck, this info helps you make up your mind on which welding process to choose for your future metalworking projects!
FAQs:
Why would you use MIG over TIG?
MIG processes are ideal for applications requiring high-volume welding with excellent strength, ductility, and root pass efficiency. MIG is also used for heavier gauges than TIG and is widely regarded as the most user-friendly of the arc welding processes.
Should I learn MIG or TIG welding first?
If you’re new to welding and want to use both MIG and TIG, I would suggest starting with MIG because it is easy to learn & suitable for beginners. Mig Welding is an arc welding process using a consumable electrode wire fed through the weld pool by continuously arcing at a high amperage electric current.
What can MIG do that TIG cant?
MIG welding has a higher deposition rate and can be made continuous during traverse feeding. MIG produces more consistent finish welds, especially on steep surfaces. In contrast to TIG, it’s possible to produce heavier welds because MIG uses an electrode that is fed wirelessly through a gun. In addition, it doesn’t require preheating or post-heating of the base material and is better for horizontal applications than TIG.
Which is the strongest weld, MIG TIG or stick?
TIG welding is a very conducive process for achieving high-quality welds with low penetration and high strength, whereas stick welding produces a rougher surface but is still very strong.
What are the 3 disadvantages of TIG welding?
The three disadvantages of TIG welding are:
1) TIG welding is difficult to learn
2) TIG welds have the potential to be inconsistent
3) TIG welders tend to be expensive
