The Three Main Arc Welding Processes
Every fabrication shop runs at least one of these. Each has strengths. Choosing the right one depends on the material, thickness, appearance requirements, and production volume.
TIG Welding (GTAW)
Gas Tungsten Arc Welding. A non-consumable tungsten electrode creates the arc. The welder manually feeds filler rod with the other hand. Argon gas shields the weld pool.
Best For
- Thin materials (down to 0.020″)
- Stainless steel, aluminum, titanium, copper alloys
- Cosmetic welds — smooth, clean, Instagram-worthy beads
- Pipe and tube welding
- Aerospace and food-grade applications
Limitations
- Slow — 2–5x slower than MIG on thick material
- High skill requirement — both hands busy, foot pedal for amperage
- Not practical for heavy structural steel
MIG Welding (GMAW)
Gas Metal Arc Welding. A consumable wire electrode feeds continuously through the gun. The wire IS the filler metal. Shielding gas (typically 75% argon / 25% CO₂ for steel) protects the weld.
Best For
- Production welding — fast, repeatable
- Steel and stainless steel (1/16″ and up)
- Structural fabrication
- Robotic/automated welding
- Less skilled welders can produce acceptable results
Limitations
- Not great for thin material (burn-through)
- Needs shielding gas — can’t weld outdoors in wind easily
- Spatter cleanup required
- Less precise than TIG on cosmetic work
Stick Welding (SMAW)
Shielded Metal Arc Welding. A consumable electrode coated in flux creates its own shielding gas as it burns. The oldest and simplest arc process.
Best For
- Field work — no gas bottle needed, works in wind and rain
- Structural steel, heavy plate
- Rusty, dirty, or painted surfaces (more forgiving)
- Pipeline welding
- Remote locations with minimal equipment
Limitations
- Slower than MIG
- Slag removal required between passes
- Rougher appearance
- Not suitable for thin materials or aluminum (without specialized rods)
Quick Comparison
| Factor | TIG | MIG | Stick |
|---|---|---|---|
| Speed | Slow | Fast | Medium |
| Appearance | Excellent | Good | Fair |
| Skill Level | High | Low–Medium | Medium |
| Thin Material | Excellent | Fair | Poor |
| Thick Material | Slow | Excellent | Excellent |
| Aluminum | Excellent | Good (spool gun) | Poor |
| Stainless | Excellent | Good | Fair |
| Outdoor Use | Poor | Fair | Excellent |
| Cost per Foot | High | Low | Medium |
What About Flux Core (FCAW)?
Flux-core is MIG’s tougher cousin. Instead of solid wire + gas, it uses hollow wire filled with flux. Self-shielded FCAW needs no gas bottle — great for outdoor structural work. Dual-shield FCAW (flux core + gas) is the productivity king for heavy steel fabrication.
Need welding or fabrication? Tell us about your project — we’ll match you with the right process and shop.