MIG Vs TIG Welding: Complete Guide to Choosing the Right Method

Arc welding is a widely used metal welding process. There are four main types of metal welding: MIG welding, TIG welding, electrode welding, and flux-cored welding. Different welding processes are suitable for various situations. MIG and TIG welding are the most popular of these four main types because of their weld quality, productivity, and other advantages.

Both metal welding processes have their techniques, advantages, and disadvantages and produce different results. Therefore, they can be used in different situations. To choose the best welding method for your project, you need to understand the differences between MIG and TIG welding. This article will explain the differences between MIG and TIG welding, including their advantages and disadvantages, uses, and tips for choosing the best method.

Overview of the TIG and MIG Welding Processes

To compare TIG and MIG welding, it is important to understand how each process works. The following is an overview of how the two welding methods work.

Process Principle of TIG Welding

TIG welding, also known as gas tungsten arc welding, is an arc welding process. It uses a non-consumable tungsten electrode in the torch to produce an electric arc. The arc generates the heat needed to join the metal pieces together. The heat generated melts the electrode that is added to the weld pool.

In addition, the arc is surrounded by an inert gas (usually argon) emitted from a gas nozzle. This gas protects the arc from the surrounding air. As a result, TIG welding produces stronger, deeper welds. However, it takes more time because the welder must add the filler material manually.

Process Principle of MIG Welding

MIG welding is a type of arc welding and is suitable for both thick and thin metals, including aluminum and copper. An electric arc is generated at the end of a consumable electrode, which forms a weld pool with the workpiece. The weld pool is protected by a gas emitted through a nozzle on the arc. The main protective gas is carbon dioxide, as it is common in the atmosphere.

Since MIG welding is semi-automated. Therefore, the feed rate of the electrode and the size of the arc are influenced by the power source. In addition, the welding speed and position depend on the operator. In some cases, there is no manual part of the process and it can be said that the process is automated.

Differences between MIG and TIG welding

To choose the best method for your project, you need to understand the differences between TIG and MIG welding. The following are basic points of comparison between MIG and TIG welding.

Power Source

The type of power supply is a key factor in comparing MIG and TIG welding. TIG welding can be performed using either an AC power supply or a DC power supply. In TIG welding, the choice of power source depends on the type of metal being welded and the type of arc required. AC power sources are suitable for welding aluminum, while DC power sources are more suitable for producing a strong arc. On the other hand, MIG welding uses DC power and the current reaches the workpiece through a consumable wire.

Metal Selection

When it comes to metal selection, TIG and MIG welding are slightly different. Both methods of arc welding can be used on a variety of metals such as aluminum, carbon steel, and stainless steel. MIG welding is more suited to thicker metals, while TIG welding is more suited to thinner metals. This is because TIG welding provides better control during the welding process and helps prevent damage to the workpiece.

Electrodes

Electrodes can be positive (anode) or negative (cathode). They help to produce an electric arc, which is why they are called arc welding. Sometimes they are also used as filler material. There are usually two types of electrodes, consumable and non-consumable.

Consumable electrodes produce an arc and are used as filler material. They are made of materials such as mild steel and nickel steel, have a low melting point, and are used for MIG welding. Non-consumable electrodes produce an arc without melting during the welding process. Examples include copper-clad carbon, graphite, and tungsten for TIG welding.

Shielding Gas

Shielding gases protect the weld zone and the metal to be welded from atmospheric contaminants. Carbon dioxide is the most widely used shielding gas for MIG welding. Other gases that can be used include helium, argon, and oxygen. They work better on certain metals, such as aluminum.

On the other hand, in TIG welding, argon is the protective gas. Sometimes a mixture of helium and argon can be used, such as when welding materials with a high nickel content. In addition, when welding stainless steel, a common type of shielding gas mixture is argon and nitrogen or argon and hydrogen.

Welding Torch

The head includes the electrode and the gas nozzle, while the welding torch is a part of the head. These parts play different roles in the welding process. To function properly, they need to be cooled with gas or water while the welding is taking place. Therefore, it is important to understand the torch when comparing MIG and TIG welding.

Both TIG and MIG welding use air-cooled or water-cooled torches. Air-cooled torches use gas to cool the nozzle. Although air-cooled torches are less efficient, they are portable and less expensive. On the other hand, a water-cooled torch is better suited for heavy-duty work because water cooling is more efficient. Although both types are used in both welding processes. However, TIG welding relies more on water-cooled torches because they generate more heat.

Welding Quality

This is the key factor in comparing MIG welding with TIG welding. Most sheet metal fabricators prefer TIG welding to MIG welding. This is because it produces a smooth and beautiful weld. Therefore, TIG welding is the best choice for materials that need to be aesthetically pleasing.

Speed

Another key difference in welding is the speed of the process. MIG welding is faster than TIG welding. However, there is more attention to detail in TIG welding than in MIG welding. In addition, TIG welding uses filler material, whereas MIG welding does not. Therefore, if you want to weld quickly, you can use MIG welding.

Price

Another difference between TIG and MIG welding is the cost, which is higher for TIG welding. To produce a high-quality weld, additional material is usually required. In addition, it usually requires more detailed work, takes longer, and requires more power.

Choosing between MIG and TIG welding can be difficult. You can contact us and Yonglihao Machinery will help you choose the best way. In addition, we can also provide you with sheet metal fabrication services including welding.

Advantages and Disadvantages of TIG and MIG Welding

TIG and MIG welding can be used to join various metals. There are advantages and disadvantages to both methods and understanding them can help you choose the better method.

Advantages of TIG Welding

• TIG welding is precise and careful
• The welded metal looks good
• TIG welding is more environmentally friendly
• Better control of the operation
• It uses non-consumable electrodes, which reduces maintenance and operating costs

Disadvantages of TIG Welding

• TIG welding is more expensive because it takes longer and uses filler material
• Requires a clean welding surface
• Requires an experienced person to operate
• The welding process takes more time

Advantages of MIG welding

• Faster welding speeds
• Lower cost than TIG welding
• MIG welding is also highly accurate
• Automated or semi-automated
• Equipment is easier to obtain
• Neat and clean welds

Disadvantages of MIG welding

• The lower strength of welded joints
• Less reliable than TIG welding due to arc stability problems
• It is not good for the environment as it produces fumes and gases
• It may lead to rusting
• MIG welding may burn thin material due to poor control of the operation
• Protective gas is required when working indoors
• Each metal has its own welding needs

Uses of TIG and MIG Welding

To choose between MIG and TIG welding, you need to know when to use both methods. We think you can look at both the pros and cons of choosing the right method. Therefore, we will only discuss the uses of these two arc welding methods.

Uses of TIG Welding

Unlike MIG welding, TIG welding is more suitable for manual and machine welding. It is therefore suitable for welding pipes and pipelines. In addition, TIG welding is also suitable for welding metals in aviation and aerospace. Here are some of its uses:

• Welding Thin Metals: TIG welding works well for welding thin metals. This is because it is precise, and accurate and allows for better control during operation. And it does not require cleaning.
• Welding Aluminum and Other Metals: TIG welding is suitable for welding different metals, including aluminum and copper. It can also be used to weld rare metals such as titanium. However, it cannot be used to weld cast iron.
• Short Production Cycles: TIG welding is suitable for shorter production cycles. Using TIG welding for longer production runs can make welding more complicated and expensive.
• Aesthetics: TIG welding can be used for projects where the result needs to be aesthetically pleasing. For example, it can be used to create artwork, decorative patterns, and automotive projects.

Uses of MIG Welding

MIG welding is the most commonly used method of welding sheet metal in the automotive and home improvement fields. Here are some of its uses:

• Large Metal Parts: MIG welding is ideal for welding large, thick metal parts. It works by using filler material to weld the parts together as they solidify. However, you may need to smooth the welded part.
• Products with Fewer Defects After Welding: Welded products that require fewer defects are often welded using MIG welding. This welding technique is continuous, which means it doesn’t rise and fall like TIG welding. As a result, there is less chance of defects occurring during the welding process.
• Long Production Cycles: MIG welding is ideally suited for long production runs. This is because it is easy to use and works perfectly with a wide range of materials.
• Low Operating Requirements: MIG welding is easy to perform without much-specialized skills. In addition, it is suitable for handling large projects because it is easy to use.

Why is MIG Welding Better than TIG Welding?

Many sheet metal fabricators consider MIG welding to be better than TIG welding. The reasons for this are obvious, and the following are some of the main ones:

• Versatility: MIG welding can weld more types of material than TIG welding. Consumable electrodes help create the arc and act as fillers, making them ideal for welding two different metals.
• Speed: MIG welding is faster than TIG welding. Because it uses automatic or semi-automatic machines, and the MIG torch can run continuously. This makes it more efficient and productive than the more detail-oriented TIG welding.
• Ease of Use: MIG welding is easier to learn and use than TIG welding, which requires a higher level of expertise. a MIG welder can weld sheet metal with one hand, whereas a TIG welder needs both hands and a foot to do his job properly.

Summary

Of the four main metal welding processes used in sheet metal fabrication, MIG welding, and TIG welding are the most commonly used and compared by manufacturers. Each of these two welding processes has its benefits, and choosing one means you need to understand their techniques, advantages, disadvantages, and other differences. Understanding these factors will help you choose the right welding method for your job.

If you have questions about MIG welding or TIG welding. Contact us and Yonglihao Machinery’s team of professionals will help you find the best solution. Yonglihao Machinery is also the best partner for your welding needs. As a rapid prototyping company, we specialize in manufacturing sheet metal parts for mass production. We are committed to providing quality welding services quickly and at a favourable price to meet your needs.