MIG VS TIG Welding: What’s the Main Differences?

MIG VS TIG Welding

Have you decided to do some welding? Or, maybe you’ve already got a welding project and are eager to learn more about MIG or TIG welding. No matter which method you decide to use, there are certain differences between the two techniques.

Let’s explore these differences and why they might make sense. We hope you enjoy the guide and learn more about MIG or TIG welding!

MIG VS TIG Welding

TIG welding is the best method for welding thin and large metal sections, but it can also cause unwanted effects on the surrounding area.

MIG welding, on the other hand, is a safer option when welding larger sections, as the heat generated in the arc does not penetrate the weld zone as deeply. This means the weld zone remains intact and does not melt into the surrounding metal, like in the case of TIG.

MIG and TIG welding are popular methods for welding metals of different thicknesses.

When welding metals of different thicknesses, one must pay attention to the heat input or depth of penetration as it affects the welding characteristics.

A greater heat input should use to weld thinner metals.

However, a larger heat input produces excessive heat that penetrates deeper and may melt the weld zone. Thus, the correct heat input should be applied depending on the type of metal being welded.

As such, welding thicker metals may require less heat input and produce a cleaner weld.

TIG welding is generally used for welding metals no thicker than 0.03 inch (1mm) and requiring the least heat input.

MIG welding is best suited for welding metals that range in thickness from 0.1 to 1.5 inches (2-35mm).

The Best Welder for the Job: TIG vs MIG

Here is how to choose the best welding method for the job:

Use a tungsten electrode and a TIG welding gun when welding a piece of sheet metal between 0.15 to 0.5 inches (3-12mm).

When welding a piece of sheet metal thicker than 0.5 inches (12mm), use a tungsten electrode and a MIG welding gun.

MIG welding is good for thick steel (0.15-1.5 inches/ 3-35mm).

This is because the MIG welding gun emits low heat; thus, the MIG welding process is ideal for welding sheet metals thicker than 0.5 inches (12mm).

It is ideal for welding a thick section of steel because the heat generated by the welding process is concentrated and does not penetrate the weld zone.

You may also need to weld thick sheets of aluminum, stainless steel, copper, etc.

In all these cases, the MIG welding gun is the best choice.

This welding technique is ideal for these types of welds as the heat is concentrated at the welding point and not the surrounding metal.

MIG vs TIG – How They Work

Before discussing MIG and TIG welding, let us first understand these two methods and how they differ.

First, let’s go over MIG welding.

MIG Welding Process

MIG Welding Process

When welding using a MIG welding machine, the tip is usually made of copper and inserted into the molten weld pool. The MIG machine’s power supply regulates the current and voltage between the tip and the workpiece.

Gas is fed into the torch through the tip, held at a low pressure which blows the gas onto the molten weld puddle. When welding, a wire, stick, or arc will be connected to the metal being welded, making a MIG weld. 

The gas shield protects the metal from oxidation and prevents contamination. It is also important to note that there are a few types of MIG welding, including stick welding, plasma welding, oxyfuel welding, and wire welding.

MIG welding is a versatile welding process utilized in many industries. It is often the go-to process when welding steel and stainless steel. The weld will be of excellent quality, and several variations of this welding method exist. When using MIG welding, you may want to use a stick or an arc, and you will need to select the right tool for the job.

TIG Welding Process

TIG Welding Process

TIG welding is similar to MIG welding except for how it is used. Besides, TIG welding is a type where the gas is the same as the arc or electrode. The tungsten electrode will get hot and be submerged in the weld pool, made up of a filler material and shield gas. 

The shielding gas is similar to the way that is used in MIG welding to prevent contamination. The difference is that the TIG welding machine does not have an arc; rather, a hot metal tip is directly heated.

The metal will melt, the molten pool will form, and the filler material will add. The welding process is consumable, meaning the tip will become consumed. The process is used in many industries but is most commonly used in shipyards and construction industries.

MIG welding and TIG welding are widely used and have benefits and drawbacks. Before deciding which to use, you must consider the types of welds you will make and your needs.

MIG Vs TIG – Weld Differences

So what’s the difference between MIG welding and TIG welding? Are they similar, or are they different?

While both are welding technologies, each has pros and cons and is used in the industry. MIG welding was originally designed to be safer and easier for beginners, while TIG welding was developed for experienced welders. This is because of their differences in how they are done.

Weldable Metals

MIG welding involves using metal electrodes to arc-weld metal pieces together. In comparison, the TIG welding torch uses a consumable wire, which is melted and fed to the base metal. The two processes also differ in the shape of the arc. The TIG is a cone-shaped arc, while the MIG is circular or square.

The MIG arc tends to melt the metal on the sides of the joint first, but not always. It does this because the metal at the tip of the arc is always higher, generating more heat.

Weld Speed

MIG welding is usually carried out at slower speeds, and the power settings vary depending on the thickness and type of metal used.

However, the MIG is cheaper than TIG, but TIG can produce thicker better quality welds.

MIG is less expensive to run than TIG. However, this depends on the model and the size of the weld. MIG welding equipment is heavier and larger than TIG, so it can cost more to transport.

TIG is more popular in the USA than MIG. It is still commonly used by professionals and for repair work.

Welding Gas

Regarding the end result, most of the peoples confused about can they use the same gas? While MIG welds tend to be cleaner since there is no flux or filler wire to contaminate the weld. In comparison, a TIG weld tends to be more rust-resistant. TIG uses argon as the shielding gas, which has a high affinity for oxygen, reducing the risk of oxidation. MIG welding, on the other hand, uses an inert gas, such as helium.

Weld Aesthetics

MIG welding uses a smaller electrode than TIG and produces less heat. Therefore, it is used for welding thin metal layers or very small items. TIG welding uses a higher current than MIG and a larger welding torch, so it’s good for large metal pieces and thicker layers.

Overall Comparison Between TIG VS MIG


In general, the two processes aren’t too different, although they have their own advantages. The main benefits of TIG welding are that it can produce better quality welds and is slightly easier to use. The main benefit of MIG welding is that it is cheaper and it produces a cleaner weld.

Overall, they’re very similar but have some slight advantages and disadvantages. To decide which one you should go for, you need to weigh the pros and cons of each process, and the final decision is up to you.

When To Use TIG And MIG Welding

In the past, we might have thought of welding as a way to solve a problem. The idea of the gas tungsten arc welding process was that you could use a torch to create a weld across a joint quickly, but they’re no consumables used.

Today, technology is completely different. We no longer rely on filler wire, filler metal or flux. Instead, we use our imagination to use advanced techniques like MIG welding and TIG welding to accomplish the work of welding. There are multiple advantages to using this type of welding.

MIG welding gives us a lot of flexibility in how we use it.

In MIG welding, we use gas instead of filler material and deposit metal onto the weld as we move along. We can do a lot of things that we couldn’t do before when we were using the tungsten arc process.

It allows us to use an electrode rod as a filler metal. Instead of a filler wire, we’re using an electrode rod, which provides a nice flow to the weld.

We can also do some interesting things when we combine these two technologies. The ability to deposit multiple metals together, whether aluminum and steel or aluminum and stainless steel, makes MIG welding the perfect technique.

TIG welding is another advanced welding process that we can use to save money. TIG welding does allow us to use consumables, so we can save on filler material and filler wire. It also allows us to perform arc welding without the filler metal and do a much cleaner weld.

Because it’s clean, it’s easier to machine, so we can use it for applications where we need to cut through an object. For example, we might use it to cut out a hole in a part of the assembly.

When you combine these two advanced welding techniques, you can create new products. For instance, you could take a MIG weld and weld that to an aluminum piece to create a new piece of machinery. Or you can take a TIG weld and weld that to a stainless steel plate and create a new product.

We can use MIG and TIG welding to achieve the same results. To do this, you need to ensure that you’re learning the differences between the two welding methods and finding the right balance.

If you choose to take your welding skills to the next level, you’ll find that using these techniques will allow you to complete any welding job that comes your way.


Is TIG welding harder than MIG?

The difficulty of welding depends on various factors, such as the type of metal being welded, the welding process used, and the welder’s skill. However, TIG welding is typically more difficult than MIG welding because it requires a higher skill and experience.

What is better for welding aluminum TIG or MIG?

MIG welding is better than aluminum welding because it has a lower heat input and produces less spatter. Some factors that may influence the choice of welding method include the type of aluminum being welded, the size and shape of the welds, and the welding equipment available.

Which is the strongest weld, MIG TIG or stick?

Stick welding is the weaker weld, but it can be done with a TIG torch. MIG welding is the stronger weld but requires a more expensive torch and training.

Which is better, TIG or MIG welding?

MIG welding is better than TIG welding for most applications. The main reason is that MIG welds are more consistent and produce stronger joints.


MIG welding and TIG welding are both welding techniques. Which one should you use? That is up to you. They are both very strong and work well for most applications. MIG welding uses a welding rod that melts to connect two metal pieces. 

TIG welding is more powerful than MIG welding and is used for larger projects like pipe bending. You can use either or. Ultimately, it depends on the project, budget, and skill level.

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