MIG, TIG, and Stick are the three most common welding processes, and each one exists for a reason. There’s no single “best” process. The right choice depends on the material, the application, and the result you need. Here’s how they compare and when to use each one.
MIG Welding (GMAW)
MIG stands for Metal Inert Gas, though the technical name is Gas Metal Arc Welding (GMAW). A continuously fed wire electrode melts into the joint while shielding gas (typically a mix of argon and CO2 for steel) protects the weld pool from atmospheric contamination. The process is defined under AWS standards and is one of the most widely used welding methods in manufacturing.
How it works: You pull the trigger on the MIG gun, the wire feeds automatically, and you guide the gun along the joint. The machine controls wire speed and voltage. Your job is travel speed, angle, and distance from the workpiece.
Strengths: MIG is fast. It’s the most productive process for mild steel and produces clean welds with minimal cleanup. It’s easy to learn, easy to automate, and works well on material from thin sheet metal up to 1/2″ plate. Most production metal fabrication shops, including ours, use MIG for the majority of steel work.
Limitations: MIG requires shielding gas, which means it doesn’t work well outdoors in wind. The equipment is less portable than Stick. And while MIG can weld aluminum with the right setup (spool gun or push-pull gun), it’s not ideal for it compared to TIG.
Common applications: automotive fabrication, structural components, machine guards, railings, brackets, trailer builds and repairs, production runs, general shop work.
TIG Welding (GTAW)
TIG stands for Tungsten Inert Gas, technically Gas Tungsten Arc Welding (GTAW). A non-consumable tungsten electrode creates the arc, and you manually feed a separate filler rod into the weld pool. Shielding gas (pure argon for most applications) protects the weld.
How it works: One hand holds the TIG torch, the other feeds filler rod. A foot pedal controls amperage in real time, giving you precise heat control. It’s a two-handed, one-footed operation that requires coordination and practice.
Strengths: TIG produces the highest quality welds of any manual process. The heat control is precise, the welds are clean, and there’s virtually no spatter. TIG can weld almost any metal: steel, stainless, aluminum, copper, titanium, and exotic alloys. For thin materials and cosmetic welds, nothing beats TIG.
Limitations: TIG is slow. It’s the least productive of the three processes for thick material. The learning curve is steep. And the equipment costs more than MIG or Stick. TIG also requires very clean material surfaces to produce quality results.
Common applications: aluminum welding, stainless steel food-grade or sanitary welds, thin wall tubing, aerospace components, artistic metalwork, pipe welding, and any application where weld appearance or purity matters.
Stick Welding (SMAW)
Stick welding is formally called Shielded Metal Arc Welding (SMAW). A consumable electrode (the “stick” or “rod”) is coated in flux. When you strike an arc, the electrode melts into the joint while the flux coating creates a gas shield and deposits a protective slag layer over the weld.
How it works: You clamp the electrode into a holder, strike it against the workpiece like a match to start the arc, and then maintain a consistent arc length as the rod melts down. It’s the most basic setup in welding: a power source, a ground clamp, an electrode holder, and rods.
Strengths: Stick welding works anywhere. No shielding gas means wind isn’t a problem. It handles dirty, rusty, and painted surfaces better than MIG or TIG. The equipment is simple, portable, and affordable. Stick is the go-to for outdoor field repairs, pipeline work, and structural steel. Many structural steel codes, including the widely used AWS D1.1 Structural Welding Code, are written with Stick welding procedures in mind.
Limitations: Stick is slower than MIG and produces more spatter and slag that needs to be cleaned off. It’s difficult to use on thin material (under 1/8″). Electrode selection matters: different rods are designed for different positions, materials, and applications. And the process generates more heat input, which can cause warping on thin parts.
Common applications: structural steel erection, pipeline welding, farm and heavy equipment repair, outdoor field repairs, industrial machinery repair, and any situation where portability and surface tolerance matter more than cosmetic appearance.
Quick Comparison
Easiest to learn: MIG. You can lay a decent bead in your first hour of practice.
Cleanest welds: TIG. No spatter, no slag, surgical precision.
Most versatile conditions: Stick. Works in wind, rain, on dirty metal, in the field.
Fastest for steel: MIG. Highest deposition rate for production work.
Best for aluminum: TIG. MIG can do it, but TIG does it better.
Most affordable setup: Stick. A capable machine and a box of rods for under $400.
Safety Across All Processes
Regardless of which process you use, welding safety fundamentals don’t change. OSHA’s welding, cutting, and brazing standards cover the baseline requirements for protective equipment, ventilation, and fire prevention. At minimum, every welder needs a proper helmet, gloves, flame-resistant clothing, and adequate ventilation. The Lincoln Electric safety resource center also has practical guidelines worth bookmarking.
Which Process Do We Use?
All three. At Iron Mann Industries, we’re certified in MIG, TIG, and Stick welding with AWS Level I and Level II credentials. The process we choose depends entirely on the job. A custom fabrication project in mild steel gets MIG. An aluminum component gets TIG. A field repair on a piece of industrial equipment gets Stick. Having all three in-house means we pick the right tool for the job instead of making one process do everything.
If you’ve got a project that requires professional welding, whether it’s a single repair or a production run, give us a call at (810) 407-7585 or request a quote. We’ll help you figure out the right approach.