MIG and TIG differences
What is the difference between MIG and TIG welding?
In the 1940s, when traditional welding methods failed to join aluminum and magnesium alloys together, metal inert gas (MIG) and tungsten inert gas (TIG) welding, powered by innovative welding machines, emerged as breakthrough solutions. This success led to their widespread adoption across various industries, a trend that continues to this day. While they are quite similar on the surface, our professional local welders here at Top Peak Welding will tell you that each has its own distinctive features.
What is MIG welding?
Metal Inert Gas welding process became popular in the UK for welding aluminum using argon and for carbon steels using carbon dioxide. MIG welding is an attractive alternative to manual metal arc (MMA) welding, offering high deposition rates and productivity.
How it works
- A wire is fed from a reel by a motor drive through a copper contact tube contact tip, and the welder moves the welding torch along the joint line to conduct welding current into the wire.
- An arc is struck between the end of a wire electrode and the workpiece, melting both to form a weld pool. The wire serves as both a heat source via the arc at the wire tip and filler metal for the welding joint.
- The weld pool is protected from the atmosphere by shielding gas fed through a nozzle surrounding the wire at a 15 to 25 cubic feet per hour flow rate.
Wires may be solid (simple-drawn wires) or cored (composites formed from a metal sheath with a powdered flux or metal filling). The process offers high productivity, as the wire is continuously fed, and consumables are competitively priced.
What is TIG welding?
TIG welding is a highly versatile method that uses a foot pedal for precise control over the heat introduced to the metal. This makes it well-suited for bench or shop work where the material is at a comfortable angle.
How it works
- The arc is formed between a non-consumable pointed tungsten electrode and the work piece.
- When filler metal is required, the welder, using their other hand, must add it separately to the weld pool.
- The tungsten electrode heats and liquefies the material to be welded.
- 15 to 25 cubic feet per hour of shielding gas escapes from the gas nozzle, which protects the heated material and the liquid molten pool.
This process uses an inert gas shield, typically 100% argon, to protect the weld pool instead of a slag.
Comparing MIG welding and TIG welding: Pros and Cons
Are certain types of welding best for certain metals?
- Stainless Steel - Since this metal has low conductivity alloys, it retains heat longer. TIG welding is ideal for creating narrow beads and avoiding critical areas. However, MIG welding may benefit some mass productions.
- Mild Steel and Cast Iron - MIG welding is popular for mild steel and cast iron due to its ease of use, strong welds, and high deposition rates. Though MIG welds aren't always aesthetically pleasing, surface coatings usually cover them.
- Aluminum - Minimizing bare aluminum's exposure to air is crucial to prevent aluminum oxide formation. TIG welding, especially in AC mode, cuts through oxide layers and ensures clean welds. While both processes work for metals like copper and titanium, TIG is preferred for thin aluminum to ensure spatter-free, clean welds.
- Thin metals - TIG welding is capable of joining a wide range of small and thin materials. Filler metal is optional because pieces can be fused by melting the groove together. TIG welding is preferred for thin materials (0.6mm and thinner) that are delicate and prone to defects, with applications including pipe joints, aerospace, and automotive fabrication. In MIG Welding, welding thin metals that are below 0.8mm is not recommended.
Which welding process is cheaper? MIG or TIG?
Generally, MIG welding tends to be cheaper due to its less expensive welding machines and materials, faster speed, and simpler setup. The wire used in MIG welding is more economical than the tungsten electrode used in TIG welding. Due to the production of fumes in MIG welding, additional protective equipment is required. TIG welding is slower, increasing production times and costs, and it’s more expensive due to lower deposition rates and preparation.
Specific project requirements and materials being welded can influence overall costs. To know more, you can talk to our professional welders who have extensive experience in production planning. Call Top Peak Welding at 719-259-3359.
Which weld is stronger?
TIG welded joints are typically stronger than those produced by MIG welding because the narrow, focused arc created by TIG welders offers better penetration of the metal. When applied correctly, TIG weld beads contain few holes and other defects, resulting in a stronger weld.
Which process is faster?
MIG welders are favored for their rapid welding speeds in production settings, thanks to automatic filler material feeding and an air-cooled mechanism. This method is named the "hot glue gun" of welding, where welders simply pull the trigger to initiate or cease the weld.
MIG welding is ideal for long runs due to its continuous wire feed, providing a constant heat source and eliminating frequent stops. Its broad arc dissipates heat efficiently, allowing welders to maneuver the weld puddle swiftly and execute longer runs without overheating, greatly reducing the time to complete projects.
MIG welding also offers a quicker setup since it doesn't involve preparing tungsten electrodes or cutting filler rods to size. Additionally, MIG welding yields less splatter and needs minimal post-weld cleaning compared to TIG welding. In contrast, metals must be clean and well-prepared for TIG welding.
Do you have a welding need that needs to be done ASAP? Contact us now, and our highly skilled professionals can get it done in no time.
Which welding method is easier?
MIG welding is easy to learn since it requires only one hand to operate with the filler material automatically fed through the gun. Without a foot pedal to master, it allows for easy welding at various angles and produces continuous, low-defect welds that need little or no finishing. On the other hand, TIG welding is challenging to learn because it requires two hands and a foot pedal for control, so skilled practitioners are required for precision and accuracy.
Which process will look cleaner once completed?
TIG welds tend to show better aesthetic qualities than MIG welds. With very little or no spatter, TIG welds usually only require light polishing to finish and remove any discoloration. TIG welded stacks of 'coins' are often seen as the most aesthetically pleasing welds and can make unpainted welds in steel or aluminum look their best. In contrast, since MIG welding isn’t as precise due to the difficulty in controlling the weld bead, their welds are not as visually tidy as those produced by a skilled TIG welder.
Conclusion: What’s best for my project, MIG welding or TIG welding?
Both methods have their merits: MIG is cost-effective and easy to use, while TIG offers precision and quality. TIG welding offers superior strength and aesthetics when handled by skilled professionals, while MIG welding's quicker setup and speed make it more efficient for longer runs.
At Top Peak Welding, we will evaluate your project's requirements and recommend the best approach. Whether you need MIG for thicker materials or TIG for precise work, our experts are equipped to handle any job, no matter how complex. Looking for a local welder to help with your project? Contact us now for a free quote and we’ll fabricate your ideas into reality. Speaking of fabricating: now that you're done reading this comparison, check out all of the other services we offer from
fabrication to
metal architectural work throughout Colorado Springs, Denver, and Pueblo.
