Mig vs Tig Welding: How to Choose the Right One?

One of the most employed manufacturing techniques is welding. It uses filler material and heat to join different materials together. There are numerous welding processes; however, two of them are precise and versatile when it comes to joining materials. MIG (Metal Inert Gas) and TIG (Tungsten Inert Gas) are the two versatile welding methods. Although both methods require an externally supplied filler material and inert shielding gas to combine base metals, they differ. They differ in operator skill requirement, quality of weld they give, and workpiece thickness capabilities.

Let’s examine the foundations of MIG and TIG welding, as well as the benefits, drawbacks, and variations in the weld properties that may make one method better. A thorough understanding of various welding techniques will enable you to confidently choose the best option for your unique application requirements and production objectives.

Table of Contents

What Is Mig Welding?

MIG welding

MIG welding employs a constant-voltage power source to generate an electric arc, which fuses the base metal with a filler wire fed constantly via the welding flame. Concurrently, an inert shielding gas is also supplied through the gun to screen the weld pool from air contamination. (Inert gases do not react with the weld pool or the filler material.)

For heavy-duty manufacturing tasks like metal gates, MIG welding is typically utilized. It is far faster than TIG welding, which reduces lead times and production costs. MIG also generates welds requiring little to no finishing and cleaning, making it easy to learn. Nonetheless, TIG will always be the preferred method when producing accurate, robust, and exceptionally clean welds, which is the primary goal.

What Is Tig Welding

TIG welding

Tungsten inert gas welding, commonly known as gas tungsten arc welding (GTAW), is a method of joining metal components using a welding current. An inert gas is fed into the welding flame and runs along the welding arc to keep the metals from oxidizing and generating small circular gaps. The welding torch contains a tungsten electrode with a greater melting point than most metals.

Mig vs. Tig Welding: Differences Comparison

There are occasions when MIG and TIG welding are confused. Despite their similarities, a few significant variances should be noted.

Feature	MIG Welding	TIG Welding
Electrode Type	Consumable solid wire	Non-consumable tungsten electrode (separate filler rod needed)
Shielding Gas	Mixture of Argon and CO2 (or other)	Pure Argon or Helium
Process	Arc welding with continuously fed electrode	Arc welding with separate filler rod manipulated by hand
Material Thickness	Good for thicker materials	Better for thinner materials
Cost	Generally lower initial cost	Generally higher initial cost

Material Compatibility and Thickness

Although there is a slight variation between the two procedures, material compatibility is not relevant when comparing MIG vs. TIG welding to the power source. Stainless steel, carbon steel, and aluminum are among the materials that both welding techniques can use. Nevertheless, consider the material’s thickness when deciding between the two approaches. Due to its superior operational control and decreased propensity to harm the workpiece, TIG welding is a better option when working with heavy metals.

Cooling System Used for Welding Torch

The right coolant may efficiently dissipate a welding torch’s immense heat output. The two most popular coolants used in welding are gas and water. In colder climates, air conditioning is highly effective; in warmer climates, it is less effective. Air works better for using water than for chilling it.

TIG welding generates more heat than MIG welding, so torches with water cooling are employed. Air-cooling welding torches can still be used for these tasks, though.

Power Source

When comparing MIG vs. TIG welding techniques, one crucial factor is each process’s power source. Depending on the kind of metal and desired electric arc type, TIG welding employs either AC or DC power sources. Because it cleans the metal surface by removing oxide, the AC power source used in TIG welding is more suited for aluminum. On the other hand, electric solid arcs can be produced using a DC power source. MIG welding employs only a DC source.

Type of Electrode Used

TIG welding employs electrodes that are not consumable, unlike MIG welding, which uses consumable electrodes. Electrodes are used in electric conduction, arc creation, and filling applications. This is a key factor in comparing MIG vs. TIG welder since the two techniques differ in how they employ electrodes.

In electric arc welding, two kinds of electrodes are used: consumable and non-consumable. Both electrodes produce electric arcs. Consumable electrodes, however, are used as fillers during welding. Graphite, tungsten, and copper-covered carbon are examples of non-consumable electrodes, whereas mild steel and nickel steel are consumable electrodes.

Quality of Welded Parts

Another important feature that sets the MIG vs. TIG comparison apart is the quality of the welded area. Since TIG welding leaves less of a beautiful and smooth surface finish along the weld line, it is a higher-grade welding method. As a result, the superior product method demands a high level of visual attractiveness.

Type of Shielding Gases

Shielding gases shield the welding pool and workpiece from airborne pollutants during the welding process. MIG welding employs oxygen, argon, helium, and CO2 as shielding gases.

Argon, on the other hand, is used as the shielding gas in TIG welding. Combinations of argon/nitrogen (for welding stainless steel), argon/hydrogen (for welding materials with a high nickel content), and helium/argon are sometimes helpful.

Mig vs Tig Welding: Pros and Cons

Here are the advantages and disadvantages of MIG and TIG welding:

Pros of TIG Welding

TIG welding is more ecologically friendly and delivers in terms of aesthetics.
The operational control is superior.
It requires less upkeep and operating money.
Precise and accurate TIG welding

Cons of TIG Welding

The surface must be clean
It takes longer to weld something.
A knowledgeable operator is required.
TIG welding is more expensive.

Pros of MIG Welding

It is more accurate and less expensive than TIG welding.
It is automated, and the equipment is more accessible to reach.
It results in a neat weld.
The process of welding is quick.

Cons of MIG Welding

The process must take place indoors.
The instability of the electric arc makes it less dependable than TIG welding.
Rust may develop as a result.
Due to its lack of operational control, MIG welding can burn thin materials.
Smoke and fumes are produced, making it environmentally unfriendly.
It results in weaker welded joints.

Applications of Mig Welding and Tig Welding

MIG Vs TIG welding

MIG (Metal Inert Gas) welding and TIG (Tungsten Inert Gas) welding are versatile techniques used across various industries. Each method has its specific applications based on the materials involved, the required weld quality, and the conditions of the welding environment.

MIG Welding Applications

MIG welding is favored for its speed, ease of use, and suitability for various materials. Here are some of its typical applications:

Automotive Industry: MIG welding is extensively used in the automotive industry to assemble car bodies, frames, and other components. Its ability to weld thick metal sections quickly makes it ideal for manufacturing and repairing vehicles.
Construction: The construction industry utilizes MIG welding for building structures, including steel frameworks, bridges, and heavy equipment. Its high productivity and ability to produce strong welds on thick materials are crucial for these applications.
Manufacturing: MIG welding is widely employed in manufacturing processes to create various products, from small appliances to large machinery. Its automation capabilities make it suitable for high-volume production lines.
Shipbuilding: The shipbuilding industry relies on MIG welding to fabricate and repair ships. Its ability to produce strong, durable welds on steel and aluminum is essential for the structural integrity of vessels.
Pipeline Welding: MIG welding is used in constructing and maintaining pipelines due to its efficiency in welding long sections of pipe quickly and reliably.

TIG Welding Applications

TIG welding is renowned for its precision and ability to produce high-quality, aesthetically pleasing welds. Its common applications include:

Aerospace Industry: TIG welding is crucial in the aerospace industry for fabricating and repairing aircraft components. The process’s precision and ability to create clean, defect-free welds are vital for maintaining the safety and performance of aircraft.
Art and Sculptures: Artists and sculptors use TIG welding to create intricate metal artworks and sculptures. The process allows precise control over the weld, enabling detailed and visually appealing creations.
Medical Device Manufacturing: TIG welding is used in the medical device industry to produce equipment and tools that require high precision and cleanliness. Stainless steel and other biocompatible metals are often welded using TIG for these applications.
Food and Beverage Industry: The food and beverage industry relies on TIG welding to fabricate and repair stainless steel equipment, such as tanks, piping, and processing machinery. The high-quality welds are crucial for maintaining hygiene and preventing contamination.
Electronics Industry: TIG welding joins delicate electronic components and assemblies. Its precision and control are essential for avoiding damage to sensitive parts.

Conclusion

Choosing between MIG and TIG welding depends on your project’sproject’s needs. MIG welding is best for speed, efficiency, and ease of use, making it ideal for high-volume production, construction, and automotive work on thicker materials. It excels in industrial environments where time and productivity are critical.

TIG welding, on the other hand, is perfect for applications requiring precision and high-quality welds. It’s preferred for aerospace, art, medical devices, and electronics, especially with thin or delicate materials. TIG welding provides meticulous control and superior weld appearance.