MIG Welding vs TIG Welding: What Is The Differences
MIG and TIG welding methods join metals using an electric arc and a shielding gas that produces the weld. Although they are similar in many ways, they have features that set them apart. Since each of these methods has its pros and cons, it is important to obtain all the information before deciding which method to use.
In This article we will highlight the main differences between MIG and TIG welding methods. In addition, the pros and cons of each will be discussed.
What Is Metal Inert Gas Welding?
Metal inert gas welding is also called gas metal arc welding (GMAW). This arc welding process uses a continuous solid wire electrode to generate the weld using a consumable electrode filler material. Inert gas MIG welding uses a shielding gas to protect the weld from contaminants. It also uses shielding gas to protect the weld, enhance weld penetration, and reduce the porosity of the weld bead. The shielding gas and electrode are fed through a welding torch or gun.
A mixture of shielding gas containing 75% argon and 25% carbon dioxide. Other mixtures may be used depending on the materials in the welding process and other variables such as the size and thickness of the workpieces. The diameter of the continuous consumable wire electrode varies depending on the types of metals being joined, the configuration of the joint and the thickness of the part. The electrode is fed into the weld at a pace determined by the wire feed speed (WFS) settings to give enough weld to join the metal.
Metal inert gas (MIG) welding offers several benefits and differs from other welding techniques. It is versatile, simple to set up, and suitable for various types of fabrication and maintenance/repair welds. The MIG welder is a common tool for beginners and is often used for fabricating heavy-duty projects and welding rough materials onto base metals.
What Is TIG Welding?
Tungsten inert gas welding is also called gas tungsten arc welding (GTAW). The process uses an arc and a non-consumable tungsten electrode with a separate consumable filler material. This filler is a rod that is manually inserted into the weld pool; Thus both hands are used, one holding the tungsten and the other, the filler rod. The weld being made determines the configuration and size of the filler rod.
The TIG welding process uses a shielding gas that is 100% argon. Carbon dioxide is not used because it causes the tungsten to form oxide, which prematurely wears the electrode and contaminates the weld. This process also needs a foot pedal for the operator to control the current and adjust the temperature during welding.
7 Differences Between MIG and TIG Welding
MIG stands for “metal inert gas” and “TIG” stands for “tungsten inert gas.” With MIG welding, a powerful electrical current is generated through the torch and arcs through the consumable electrode, joining the metal together and reinforcing the joint with added material. In MIG welding, molten metal behaves differently in various modes of transfer, such as globular transfer and spray welding.
The TIG welding process is similar, except the electrode in the torch is made of tungsten and not consumable. A secondary filler rod of consumable material is used to reinforce the weld.
MIG welding is generally cleaner and produces less spatter compared to stick welding, making it a preferred choice for projects requiring a clean finish. There are 7 key differences between MIG and TIG welding to keep in mind for your project:
1. MIG vs TIG Welding: Process Comparison
MIG welding is easier to learn than TIG welding. This is because TIG welding involves the use of two hands, with one moving the welding torch and the other feeding the filler bar in the welding basin. In addition, there is a foot pedal used to control the current. All these movements must be synchronized to achieve the desired welding, and therefore may be difficult to master.
TIG is a more advanced welding process where associated metals must be cleaned and well prepared for this process. By contrast, the mastery of MIG welding is easier. There is no foot pedal to control and the filler is automatically inserted into the welding gun, which requires only one hand to create the welding.
Power Source
In MIG welding, a direct current source (DC) is used to create stability in the electric arc. Strength also gives enough metal penetration. In contrast, TIG welding provides versatility as it can extract power from both AC and DC sources.
However, the choice of power depends on the metal for welding, the amount of spraying in the welding basin, and the required electric arc.
Electrode
Electrode used in either MIG or TIG varies. The MIG welding process uses a consumed wire electrode that is constantly fed when two pieces of metal are attached. On the other hand, TIG uses a non-expendable electrode with a separate filler metal. As a result, buyers will use one hand to perform MIG welding instead of TIG, which is welding where they need to place one hand on the torch and the other on the filler.
Shielding Gas
In MIG welding The shielding gas and electrode are fed through a welding torch or gun. A mixture of shielding gas containing 75% argon and 25% carbon dioxide. Other mixtures may be used depending on the materials in the welding process and other variables such as the size and thickness of the workpieces.
The diameter of the continuous consumable wire electrode varies depending on the types of metals being joined, the configuration of the joint and the thickness of the part. The electrode is fed into the weld at a pace determined by the wire feed speed (WFS) settings to give enough weld to join the metal.
The TIG welding process uses a shielding gas that is 100% argon. Carbon dioxide is not used because it causes the tungsten to form oxide, which prematurely wears the electrode and contaminates the weld. This process also needs a foot pedal for the operator to control the current and adjust the temperature during welding.
2. MIG vs TIG Welding: Metal selection
If you deal with thin metals, TIG welding is preferable because it is easy to control the heat using the TIG welding process compared to the MIG welding process. When welding thin metals in vertical positions, consider using vertical down and vertical up techniques.
Adjusting voltage, amperage, and travel speed is crucial to achieve high-quality welds while avoiding excessive melt-through and burn-through, and controlling the size and shape of the weld puddle.
On the other hand, if you deal with thick metals, the MIG welding process is majorly preferred.
3. MIG vs TIG Welding: Quality
While MIG welds are strong and can be of high quality, they may not be as precise or aesthetically pleasing as TIG welds. Spatter is more common, which can affect the appearance and may require additional cleanup.
4. MIG vs TIG Welding: Speed
TIG welding is intensive process and also requires keenness to detail while using the process. This makes it slow and hard.
MIG welding is straightforward to use. This makes it a faster than TIG welding process. TIG welding is slower than MIG welding, which can be a disadvantage for high-volume production but is beneficial for detailed, high-quality work.
5. MIG vs TIG Welding: Cost
MIG welding is a cheaper welding option compared to TIG welding.
If you ask why TIG welding process is expensive, the answer is because of the quality of welding, the material used, and the higher cost of electricity it uses.
6. MIG vs TIG Welding: Pros and Cons
TIG Welding
Pros
Multi welds capable of joining a wide range of thin and small metals
Stronger , more aesthetic, and accurate welds
Filling material is optional
Cons
Slower due to more preparation work, increased production times.
An expensive process because it requires more ingredients and time.
It is difficult to learn how to perform precise and accurate welding.
MIG Welding
Pros
Short welding production time
Lower costs as materials are readily available
Easier to learn and the ability to weld from difficult angles
Easier to create welds that need little cleaning and finishing
Cons
Less durable welds due to lack of precision and strength
less aesthetically welding
Difficult to control weld beads
Welders need to be protected from fumes
7. MIG vs TIG Welding: Applications
Uses for MIG Welding
Thicker materials
When we talk about thick materials, MIG welding is the best welding method because the strength found in MIG welding is ideal for thicker metals, and they are less likely to be burned through by the process than thin materials.
Long runs
MIG welding is best for big projects that take a long time to weld and assemble because it takes significantly less time than any other welding process.
Difficult positions
If you weld unique shapes and angles, its easier with MIG welding since you don’t have to hold two separate objects. You can work with these odd parts a little easier while just holding the torch.
Large production
When we talk about faster and more affordable production process, MIG welding is best for large runs of a product or part.
Uses for TIG Welding
Thin materials
TIG welding is ideal in applications that utilize thin materials. This is because it is easy to control the heat using the TIG welding method.
Materials that can easily warp or burn are ideal for the TIG welding process.
Non-ferrous metals
Non-ferrous metals, such as aluminum and copper, are best joined using TIG welding for experienced welders
Bench or shop work
TIG welding is best used when working in your workplace or in a stable environment.
Short runs
TIG welding is the best option for you If you have small projects or only a few parts that require precision. Doing short production runs keeps the electrode from overheating while allowing you to create clean, accurate welds.
Fine or detailed work
detailed, fine welds are a TIG welder’s MO. TIG welding creates aesthetic welds that don’t require grinding down, making it the best option for precise projects.
Author
Gavin Leo is a technical writer at Aria with 8 years of experience in Engineering, He proficient in machining characteristics and surface finish process of various materials. and participated in the development of more than 100complex injection molding and CNC machining projects. He is passionate about sharing his knowledge and experience.