Diverse materials require different methods of arc welding. For example, TIG welding is preferable for thin pieces, while MIG welding is applied for welding thicker metals. TIG welding is perfect for magnesium, aluminum, and copper alloys, while MIG welding is ideal for all sorts of steel.
Here, we’re going to consider common welding methods (MIG and TIG), find out the core difference between the two processes, the Difference between MIG and TIG Welding, and point out their peculiarities, as well as pros and cons.
To see the difference between TIG and MIG welding, it is important to understand the features of each kind. So, let’s consider each variation of welding in particular first and then make a comparison of MIG VS TIG welding.
The Core of MIG Welding
There is a wide variety of welding types. But, one thing unites all of them; this is exactly the need to use an electric arc, without which the formation of a seam is impossible. And, among the wide variety, MIG welding is considered one of the most popular.
This type of welding is simple and easy to use; it is suitable for both beginners and experienced welders. With the help of MIG welding, workers can easily weld different types of metals, with different thicknesses, and any complexity of seams.
MIG (metal inert gas) welding is it is semi-automatic, manual, and automatic welding in shielding gas by fusion method. You can also find another name for the technology – GMAW (gas metal arc welding); this is the most competent and overwhelming term for the welding technology. So, both terms are used to call the same welding process.
Equipment and Accessories
To start the MIG welding process, workers need a standard semi-automatic welder. A set of welding equipment for the MIG technology consists of a semi-automatic device that reminds of a hot glue gun, a transformer (generating electrical current), gas (a reducer must be attached to the cylinder to regulate pressure), various hoses and cables, a gas burner equipped with an additional filler wire feed system, and a feeding mechanism.
MIG welding is essentially the same as welding in the environment of shielding gas with a consumable electrode. Only instead of the electrode, a filler rod is used here. Most often, the rod is made of aluminum.
The filler material is wound on a spool and automatically fed into the welding zone. The feed rate of a spool gun depends on the wire diameter and the amperage setting. All you have to do is point the welding torch at the welding area and press the button of a MIG gun.
The wire will feed into the welding zone as soon as an electric arc starts. At the same time, the gas will begin to blow over the weld pool, preventing metal oxidation and defects.
The Tech Process
The MIG welding technology implies that the edges of the joining pieces and solder are heated; they partially melt, forming a weld. But, under normal conditions, the released gases would lead to the formation of cracks and pores at the junction. In addition, metal spattering would be observed. The inert gas does not react with the liquid metal, displaces hydrogen, and prevents oxygen from entering the weld formation zone.
The role of the solder is played by the wire, which is also a consumable electrode. The filler material may vary. The weld puddle is protected by argon. After crystallization of the metal in the weld pool, a seam is obtained.
After an electric arc is formed, the melting wire begins to flow along the guides to the end of the welding torch. The wire feed speed is adjusted automatically. Some devices have functions that greatly facilitate the welding process and stabilize an electric arc. Gas is supplied to the burner under pressure. It blows the seam zone, preventing oxidation of the molten metal.
When connecting electrodes, the polarity must be observed. The choice of polarity depends on the specific conditions. In most cases, MIG welding is carried out with the direct current, but sinusoidal current can also be used.
The open circuit voltage is 30-40 V. The current strength is regulated depending on the diameter of the wire, but the thickness of the metal sheet is also of decisive importance. On some inverters, the wire feed is not adjustable, but this is a drawback since such models have an auto-correct arc function.
In addition, modern MIG welders can change operating modes. The “Short Arc” mode is relevant when the welding current does not exceed 200 A. Here, we are talking about welding the thin sheet metal. In “Spray Arc” mode, the current exceeds the specified value, and the wire diameter is 1 mm or more. For non-ferrous metals, the “Pulse Arc” mode is applicable.
Benefits and Drawbacks
The advantages of MIG welders include, first of all, productivity. If the wire feed is automated, then the process is much faster than stick welding, while quality MIG welds are achieved. Besides, nothing threatens the health of the MIG welder because the shielding gas enters only the weld puddle.
Beginning MIG welders usually face problems with igniting a heat-generated arc and holding it. The MIG arc is fairly easy to form. This means that the MIG welder is suitable for even beginning workers. Moreover, due to its pack, it is convenient to carry out work even in cramped places.
To summarize the key pros of MIG welding, let’s briefly list the main theses:
1. A longer non-stop MIG weld results in increased productivity.
2. Cheaper MIG welders.
3. Easier to learn and good for home use.
4. Less cleaning is required.
5. Deals with a wide variety of materials and their thicknesses.
Yet, many users claim that devices are too heavy and bulky. Thus, the big weight of MIG equipment makes equipment immobile and hardens portability. Besides, the welding torch is massive, which is why the welder’s hands get tired quickly. The welding zone should only be on the horizontal surface.
For a better understanding of what MIG welding is, watch this video:
Scope of Application
The semi-automatic method of welding metals is recognized as the most efficient and versatile. It has received a wide application for both industrial purposes and domestic use. The MIG welding technology has found application in the manufacture of:
- automobiles, marine vessels, and offshore structures;
- pipes and other accessories for routing plumbing systems;
- fencing and making stares at households;
- server furniture for data centers, etc.
Due to the fact that the MIG method allows welding dissimilar metals of all classes, it is actively used in many industries.
The Essence of TIG Welding
TIG (tungsten inert gas) welding is a method of joining metals that uses tungsten electrodes with shielding gas. You can find also another term in tech literature – GTAW (gas tungsten arc welding). Yet, both notions mean the same process.
Modes
TIG welding equipment works with unipolar or alternating current. Each of the individual TIG welding modes is used for different materials.
Direct Current
Equipment operating on the direct current has certain advantages. These include:
- Increasing the efficiency of the workflow.
- Seams are deeper.
- The speed of the welding process increases.
In this case, minus is fed to the tungsten electrode, and plus goes to the workpiece. DC equipment is suitable for joining alloy steels and stainless steel.
Alternating Current
In this case, an automatic change of minus and plus occurs during the operation of TIG welding devices. With an increase in the reverse polarity, the surface is more efficiently cleaned of the oxide film.
Equipment and Accessories
TIG welding requires special equipment. The minimum pack of technical devices and tools to weld using the technique includes current sources, an oscillator, an inverter, an argon balloon, a reducer, a welding torch, connecting cables, tungsten electrodes, and a filler material (wire). For full-fledged TIG welding, constant ignition is required, which is achieved due to the direct current.
The Tech Process
A tungsten electrode is a key component of a TIG welder. It melts at a relatively low temperature (about 3500 degrees Celsius), so it can be used with all types of aluminum and steel. In this case, “melting” is nominal. The electrode is considered non-consumable, which means that it must be sharpened periodically so that the arc is stable and easier to conduct.
A filler rod itself is fixed in the TIG torch. There is no need to worry about the length of the electrode since the unused length is in a special cap.
At the end of a welding torch, there is a nozzle in which the electrode is held, and shielding gas is supplied around the torch using a special button. In most cases, argon gas is used as protection. If argon is not used, then oxygen will enter the weld pool, and the quality of the TIG welded seams will be unsatisfactory. The connection will be porous and fragile; cracks are likely to appear.
Then, it is necessary to ignite the arc. It will melt the precut edges. The seam will be very reliable and tight. If TIG welders face work with gaps or need to weld an extremely strong seam that can withstand significant mechanical loads, a filler wire is used. The filler material is a rod made from the same metal that is to be welded.
The distance between the end of the electrode of the welding gun and the working surface must be at least 3 mm. TIG welders can lead the tip in different ways. If you increase the distance between the tungsten tip and the metal, the seam will be wide, and the penetration depth will decrease. When connecting thin workpieces, you have to move the torch from right to left.
To make a root seam, you need to lead the electrode evenly. Corner joints are connected at an angle of 45 degrees.
Advantages and Disadvantages
Here are the main features that give an advantage to the regarded technique when comparing MIG VS TIG processes. Despite the high temperature, the minimum deformation of the metal during TIG welding is achieved due to the narrow heating zone. Argon gas is heavier than oxygen, so air is freely expelled from the welding zone. A TIG weld is very neat and even; no mechanical processing of the seam is required. TIG devices deal with various metals, including problematic ones (like aluminum). TIG welding causes a significantly less negative impact on the environment.
To conclude on the main features of a TIG welder, here are the main theses:
1. Produces quality welds.
2. Welders can accurately control the temperature of the electrode, resulting in fewer inaccuracies.
3. No metal spattering.
4. TIG weld can be done with or without a filler.
5. Has a slower settling rate.
However, nothing is flawless. So, TIG welding has the following drawbacks. TIG welding in the open air in windy weather is complicated since the gas is literally blown out of the welding zone (the problem is solved by installing windshields, but the gas consumption level will increase significantly).
Unlike other types of welding, TIG welding requires careful preparation of the metal. Edges must be cleaned; no traces of oil and dirt are allowed; surfaces must be degreased. If you ignore this stage, then the seam will turn out to be porous and of poor quality.
The burner is designed in such a way that working in a hard-to-reach place can turn into a real problem.
For a better understanding of what TIG welding is, watch this video:
Spheres of Application
Since the TIG welding technology allows connecting diverse metals and alloys based on them, it is used in various industries:
- automotive industry and the production of parts for industrial equipment;
- space industry;
- the production of ships and aircraft;
- building frame structures;
- oil industry;
- manufacturing of medical equipment and tools.
- the production of power tools.
A TIG welder device can be used at home. With the help of TIG devices, parts from the car body are welded or radiators are repaired. However, it is important to remember here that this type of welding is the most difficult, so it is only suitable for professional TIG welders.
Now, you know all the peculiarities and subtleties of working with MIG and TIG welding. So, it’s time to proceed to the comparison of two arc welding processes.
MIG VS TIG Welding: Comparison
When forming a seam by TIG or MIG welding, welders use similar filler materials and shielding gases, as well as an electric arc. But, despite this, welding techniques and the process are very different.
TIG welding involves the use of a non-consumable tungsten electrode, which means that it is not consumed in the welding process but needs only slight sharpening. The main TIG welding difference is that during the tech process, argon is used, which can be mixed with helium or hydrogen to protect the formed seam. This technique is recommended for welding items made of alloys of copper, cast iron, aluminum, magnesium, and stainless steel sheets.
As for MIG welding, it is used when working with low-carbon steel and high-alloy materials, which greatly speeds up the process of forming the finished product. In this case, a consumable wire electrode is needed; it is consumed in the process and doubled as a filler material. This technology provides for the formation of a protective environment, which is formed by the same argon or its mixture with helium, argon and carbon dioxide, or oxygen.
MIG welding deals with a wide range of material thicknesses, starting from thin metal to thicker plates. TIG welding, on the other hand, is more commonly applied to thin materials. Usually, TIG welding is used to produce kitchen sinks and tool boxes.
We also recommend reading another article ” What are the 9 types of welding?”, we think it will also interest you and you will find useful information on this topic
The main difference between TIG and MIG welding is that one method uses a continuous electrode supply, which allows applying weld faster. Unlike MIG welding, the TIG process is much more subtle and delicate and requires more time. Another fundamental difference between MIG VS TIG welding is the type of shielding gas that is necessary for isolation from a high-oxygen environment.
Which Type of Welding is Better?
To understand which one of the two arc welding processes is better, it is important to compare TIG and MIG welding according to 11 key parameters, such as quality, tuning accuracy, process control, speed, spheres of application, and others.
Quality of Seams
Although TIG welding is inferior in speed, its seam quality is much better than that of MIG welding. A smoother process allows welders to make clean and beautiful welds. With the correct setting of TIG equipment, welders can even weld a tin can. Thus, TIG welding devices are used in various industries.
The thickness of welded materials
If we compare MIG VS TIG technologies, The TIG weld is ideal for welding thinner metals and can seam pieces of up to 6 mm. The MIG weld can be applied to thick metals of up to 40 mm.
Applied materials
As mentioned above, the TIG process is used to weld aluminum, copper alloys, magnesium, cast iron, and stainless steel. MIG welding deals with non-ferrous metals and all sorts of steel.
Speed
In comparison with MIG welding, TIG welds are a slower process. At the same time, MIG welds are less time-consuming and allow for speeding up the production process. That is why it is preferable for large enterprises and manufacturers.
Current
When comparing MIG and TIG welding, note that the first one operates using the direct current only, while the latter can be powered by both direct and alternating currents.
Setting accuracy
A properly set up argon arc (TIG) apparatus can surprise welders with its capabilities. Such equipment has many settings, thanks to which welders can customize it to their needs. However, here, MIG VS TIG welding machines have almost equal chances since the range of offered models is diverse on the modern market.
Process control
When running the MIG process, the filler metal is fed automatically. This does not allow a welder to accurately form the seam. When working with TIG, the welder independently feeds the filler material into the molten weld metal. Thus, he forms the desired seam shape, while controlling the speed of seam formation.
Convenience
Of course, here, the argon arc apparatus immediately loses to the semi-automatic device. In the first case, TIG welders have to use both hands. This can be inconvenient sometimes.
Places of application
While MIG welds can be applied both outdoors and indoors, TIG welds are made only in closed premises because the argon atmosphere dissipates easily.
Expenses on the tech process and revenues for enterprises
MIG welding takes less time on finishing products than TIG welding. Thus, enterprises can produce more items using MIG welds in a short period. The TIG welding process is more time-consuming, which means that fewer products are manufactured over the same period.
Expertise, skills, and knowledge
In comparison with MIG welding, TIG is more complicated. MIG welds are considered the best solution for beginning welders since it requires fewer skills and equipment is easier to handle. As for TIG welds, this technology requires significant skills, knowledge, and expertise.
To draw the line, note that although each kind of welding has its pros and cons, of course, it is incorrect to compare TIG and MIG welding and determine a better welding process. Yet, welders should understand that these are two completely different technologies. Each of them is designed for certain tasks and cannot replace each other. Thus, it is important to study a welding project in advance to correctly select the right welding technique to achieve the best result.
FAQ
Which is better MIG or TIG welding?
Comparing two welding processes is incorrect because they are designed for different types of works, materials, and purposes, and have their peculiarities. TIG processes are perfect for thin metals; the technology is applied more slowly but the quality is better, etc. MIG welds are made quicker and do not require special knowledge; the technology deals with a wide range of metal thicknesses. Thus, it is impossible to point out whether MIG or TIG welding is the best one. Yet, TIG is considered the most professional technology, but it is suitable for not all tasks.
Is TIG welding harder than MIG welding?
Yes, absolutely. When comparing MIG VS TIG welding, the TIG welding technology is considered the hardest one among all other methods of applying welds. To master TIG welds, welders should have a great experience, a wide knowledge base, expertise, and enough skills. Usually, welders are taught to weld using the TIG technology as the last stage of training.
Can MIG weld stainless steel?
Yes, the MIG process is suitable for welding stainless steel. But, before you start welding, it is necessary to set up equipment properly. Note that TIG also deals with pieces of stainless and mild steel sheets.
What type of welder is best for a beginner?
Experts recommend starting learning how to weld by using the MIG technology and equipment. This type is considered the best tool to start your training in the sphere of welding since it is easier to handle equipment, coordinate the process, and apply MIG welds in general. It is advisable to switch to TIG welding only after mastering the MIG welding process.
What’s the easiest welding to learn?
Generally, the easiest one is MMA (it hasn’t been mentioned in the article). They distinguish between three kinds of welding, namely MMA, MIG, and TIG. Thus, the level is complexity is relevant to the order. MMA is the easiest one. However, many welders start their experiences by trying MIG welding. It is also quite good for starting training skills, while TIG is not recommended for beginning welders.
