MIG vs TIG Welding – What is the Difference?

MIG and TIG welding are both very similar welding processes, but with subtle differences in process that can make a big difference in application. For professional metal fabricators like us, MIG vs TIG welding is more of a question of which method is more appropriate, rather than which one is better. They both use electric arcs and shielding gas to join different metals together. This makes them quite similar on the surface, but each has its own distinctive features.

The difference between MIG and TIG welding rests on these factors:

• Electrode type
• Welding process
• Shielding gas type
• Control and precision
• Weld quality
• Difficulty and skill level

Carry on reading for more detail on how these factors affect MIG vs TIG welding.

MIG welding explained

MIG stands for metal inert gas welding. This is a widely used method that creates a strong, clean weld using an electric arc. This arc forms between a continuously fed wire electrode and the metals being joined. The wire acts as the filler material, while a shielding gas protects the weld area from contamination from the atmosphere around it. It also helps with penetration and minimises porosity in the weld bead.

Both the shielding gas and the wire electrode are delivered through a welding torch. The shielding gas is typically a blend of 25% carbon dioxide and 75% argon, though other combinations may be used depending on the materials and job requirements.

The wire feed speed controls how quickly the wire is supplied. This is crucial as it ensures enough filler metal is added to form a solid join. The wire’s thickness and composition are chosen based on the type of metal being welded, the thickness of the parts, and the configuration of the welding joint.

TIG welding explained

TIG stands for tungsten inert gas welding. This is a more precise method that also relies on an electric arc, but in this case it uses a non-consumable tungsten electrode. The filler material, usually a rod, is served into the weld pool by hand. This typically requires two hands, one for the filler rod and one for the torch. 

As with MIG, a shielding gas is used to protect the weld area. However, TIG welding generally uses pure argon, as adding carbon dioxide can lead to tungsten contamination and shorten the life of the electrode.

TIG welding also incorporates a foot pedal, which gives the welder fine control over the amperage and heat applied to the metal. This allows for a more controlled and precise weld, which is particularly useful on thinner materials or more intricate jobs.

Benefits of MIG vs TIG welding

MIG welding is typically used to join larger and thicker materials together. This method is faster than TIG welding, which creates shorter production times and lowers costs. In the MIG vs TIG welding debate, MIG welding is also easier to learn, making it more accessible to beginners. However, on the other hand, MIG welds are not as strong, precise or as pleasing on the eye in comparison to TIG welding.

MIG welding wins

• Welding speed
• Cost
• Ease of use
• Ideal for thicker materials

TIG welding is best suited to joining a wide range of smaller and thinner materials. It may be slower and harder to pick up in comparison to MIG welding, which often requires a skilled metal fabricator for weld precision and accuracy. But TIG welding does offer greater control and more precise, stronger results. They are also often more pleasing on the eye too.

TIG welding wins

• Strength of the weld
• Precision
• Final aesthetic
• Ideal for thinner materials

MIG vs TIG welding – what’s better?

As mentioned in the introduction, it is difficult to choose a winner between MIG vs TIG welding because it depends on a number of factors, the main one being the application. First and foremost, if you are a skilled welder then the offer of greater weld strength and better aesthetics may make you choose the TIG option. If you are less skilled, MIG welding may be the better option. It’s relatively simple, easy to learn, and suitable for materials like aluminium, mild steel and stainless steel.

Nevertheless, as mentioned above, whether you are skilled or not the choice between MIG vs TIG welding ultimately rests on the desired application.

Difference between MIG and TIG welding applications

Understanding the difference between MIG and TIG welding isn’t just about technique, it’s also about knowing where each method is best applied.

MIG welding applications

MIG welding is an ideal choice for projects involving thicker metals and situations where efficiency is more important than appearance.

Typical MIG welding applications include:

• Automotive and transportation: Widely used to assemble vehicle bodies, exhaust systems and structural components due to its ability to join mild steel and aluminium effectively.
• Construction and structural steelwork: MIG welding is often used in the construction and security sector for beams, frames and structural supports.
• Shipbuilding and marine: The speed and strength of MIG welding makes it suitable for large scale hull and deck fabrication.
• General metal fabrication: MIG is used in workshops and manufacturing facilities to produce gates, trailers, trolleys, machinery, and other metal components where strength and speed are more important than the aesthetic finish.

TIG welding applications

TIG welding provides more control over heat input and is ideal for thinner materials, or where appearance isn’t critical.

Typical TIG welding applications include:

• Aerospace engineering: TIG is extensively used for aircraft components due to its ability to create high quality welds on lightweight, high performance metals like titanium and aluminium alloys.
• Motorsport and performance vehicles: The preferred choice for roll cages, fuel tanks, exhaust systems, and suspension parts where strength is essential.
• Pipework and pressure vessels: In industries like oil and gas, power generation and chemical processing, TIG welding is chosen for high pressure or high temperature piping where weld integrity is critical.
• Art and architectural metalwork: Fine control and aesthetic quality allows for bespoke or decorative metal fabrications.

Expert welding services at Salamander Fabrications

We have more than 50 years of welding experience here at Salamander Fabrications, meaning we know all there is to know about the difference between MIG and TIG welding. We are more than happy to share this expertise and skillset to help you achieve the goals you’re aiming for with your next project.

Additional welding methods we also provide here include:

• Spot welding: This quickly and efficiently joins thin metal sheets with discrete welds, making spot welding an ideal technique for mass production.
• Robotic MIG welding: The same basic MIG welding principles are applied but with the inclusion of robotic welder technology. This boosts efficiency and consistency.

If you would like more information on this, please visit our other blog – What Are The Different Types of Welding?

For advice or help with your next welding project you can contact us, give us a call on 01484 843599, or send an email to sales@salamanderfabs.com.