What’s the Difference between MIG, TIG, SMAW, and FCAW Welding?

For those of you new to welding the number of methods and processes can be at times overwhelming. I get it. It was for me when I started. These processes, though intended for different applications and materials, have many similarities. Nonetheless, there are four common welding processes you’ll want to learn if you plan on welding as a professional or simply as well intended “Tim the Toolman Taylor” these processes are TIG, MIG, SMAW, and FCAW. 

If you’re a novice, and you’re trying to learn the fundamentals, you’re in the right place. If you’re a professional welder looking to brush up or even offer suggestions to the magazine, welcome. 

Our starter welding guide will take you through the processes, similarities, and differences that occur during these four primary forms of welds. Lets get at it!

MIG welding

Top MIG welders comparison Table

Welder	Image	Max Amps	Volts	Process	Prices
Hobart Handler 210		210	Dual	MIG/Flux	See Price 4.5/5
Hobart Ironman 230		250	220V	MIG/Flux	See Price 4.5/5
Lincoln Power MIG 210MP		220	Dual	MIG/Flux/ Stick/TIG	See Price 4.5/5
Hobart Handler 190		190	220V	MIG/Flux	See Price 4/5
Lincoln EasyMIG 180		180	220V	MIG/Flux	See Price 4.5/5
Miller Millermatic 211		230	Dual	MIG/Flux	See Price 4/5
Hobart Handler 140		140	110V	MIG/Flux	See Price 4/5
Forney 318 190		190	220V	MIG/Flux	See Price 4.5/5
Lincoln Easymig 140		140	110V	MIG/Flux	See Price 4.5/5
Everlast Poweri 140e		140	110V	MIG/Flux	See Price 4/5
Lincoln K2185-1		70	110V	MIG/Flux	See Price 4.5/5
Lotos MIG140		140	110V	MIG/Flux	See Price 3.5/5
Forney 309 140		140	110V	MIG/Flux79	See Price 3.5/5
Miller MIG Welder, Wheeled, 200 (208)/230VAC		300	Dual	MIG/Flux79	See Price 5/5

What is MIG welding?

• Gas Metal Arc Welding (GMAW), most frequently referred to as MIG welding, is the process of continuously feeding an MIG wire electrode line through a specialized gun. The electrode forms an arc with the metal you’re attempting to weld and then melts, there by fusing your material together. 
• The method can be automatic or semi-automatic. A constant voltage, direct current source of power is most widely used in GMAW, although it is possible to use constant current systems and alternating current. In GMAW, there are four key metal transfer methods, called globular, short-circuiting, spray, and pulsed-spray, each of which has distinct properties and corresponding benefits and limitations.

How does MIG welding work?

• The MIG welding process also requires a protective gas bubble, which protects the weld against the atmosphere. 
• Because the wire is being fed onto the material however technically the metal is not actually being fused. This opens up the option to weld different types of metals together. 
• Of course, you will have to replenish your MIG wire electrode after a while as the continuous feeding wire will deplete your spool after a while. This is also the case with the gas needed to create the protective bubble around your weld.

What can MIG welding be used for?

• You might ask yourself, “What can MIG welding be used for?” A popular option for beginner and professional welders, MIG welding can be implemented in a number of different conditions and situations. A good MIG welder should be able to weld both thick sheets of metal and thin ones. 
• Quality machines have a wide range of power outputs and a monitor that will allow you to change the power so you can use softer metals without fear of burning a hole straight through it. 
• MIG welding is better suited for relatively smaller jobs. MIG welding is all about speed and a quality high efficiency weld. Welders looking to work on auto repair jobs or small structures would be primary examples of MIG users. 
• MIG welding is often considered one of the cleanest and diverse welding options around.

What are the Advantages of MIG welding?

1. Diverse welding alloy options
2. Simple to use
3. Clean welding results
4. Easy to control the weld puddle
5. Start and stop trigger
6. Many uses

MIG Welding Advantage Summary

For all welding applications no welding technique is flawless and MIG is no exception. The classic example of the drawbacks of MIG will be an agricultural or building application where welding must take place on-site, in the middle of an open field, where the wind blows. Generally speaking, MIG welding is best suited to an enclosed factory or welding store’s more regulated climate.

What are the Disadvantages of MIG welding?

1. Not strong enough for cast iron
2. To strong for aluminum
3. Needs clean work area
4. Not suitable for work outdoors
5. Portability
6. Cost

MIG Welding Disadvantage Summary

Many welders will quickly find that MIG welding equipment is more complicated and costly. MIG welding also has restricted positions for vertical or overhead welding due to the high heat input. Because MIG welding requires a more complex system, it is therefore simply less portable. That being said, it is likely you’ll have trouble successfully using one outdoors as wind and other elements will wreak havoc on the shielding gas needed to preserve the purity of the weld.

TIG welding

Top TIG welders comparison Table

Welder	Image	Max Amps	Volts	Process	Prices
Hobart Handler 210		210	Dual	MIG/Flux	See Price 4.5/5
Hobart Ironman 230		250	220V	MIG/Flux	See Price 4.5/5
Lincoln Power MIG 210MP		220	Dual	MIG/Flux/ Stick/TIG	See Price 4.5/5
Hobart Handler 190		190	220V	MIG/Flux	See Price 4/5
Lincoln EasyMIG 180		180	220V	MIG/Flux	See Price 4.5/5
Miller Millermatic 211		230	Dual	MIG/Flux	See Price 4/5
Hobart Handler 140		140	110V	MIG/Flux	See Price 4/5
Forney 318 190		190	220V	MIG/Flux	See Price 4.5/5
Lincoln Easymig 140		140	110V	MIG/Flux	See Price 4.5/5
Everlast Poweri 140e		140	110V	MIG/Flux	See Price 4/5
Lincoln K2185-1		70	110V	MIG/Flux	See Price 4.5/5
Lotos MIG140		140	110V	MIG/Flux	See Price 3.5/5
Forney 309 140		140	110V	MIG/Flux79	See Price 3.5/5
Miller MIG Welder, Wheeled, 200 (208)/230VAC		300	Dual	MIG/Flux79	See Price 5/5

What is TIG welding?

• TIG stands for Tungsten Inert Gas – named after the tungsten electrode and the inert gas shield (Argon or argon mix)
• TIG Welding can be used to weld aluminum, copper, titanium and so on, and also two metals that are different. This process is ideally suited for handling difficult welds such as curves, corners or where the weld will be visible and where precision and finish are important. 
• TIG welding allows you to weld a larger range of metals than other types of welding with better arc and weld control.

How does TIG welding work?

• You might ask yourself, “What can TIG welding be used for?” and that would be a good question. Though very popular, TIG welding provides a welder with a much more limited range of metals and metal thickness options. Though it can weld aluminum and steel, the materials are generally going to be on the thinner side.
• That said the tungsten rod used to fill the weld area is much thinner than a SMAW rod and therefore allows you to be more precise with your welding projects.

What can TIG welding be used for?

• You might ask yourself, “What can MIG welding be used for?” A popular option for beginner and professional welders, MIG welding can be implemented in a number of different conditions and situations. A good MIG welder should be able to weld both thick sheets of metal and thin ones. 
• Quality machines have a wide range of power outputs and a monitor that will allow you to change the power so you can use softer metals without fear of burning a hole straight through it. 
• MIG welding is better suited for relatively smaller jobs. MIG welding is all about speed and a quality high efficiency weld. Welders looking to work on auto repair jobs or small structures would be primary examples of MIG users. 
• MIG welding is often considered one of the cleanest and diverse welding options around.

What are the Advantages of TIG welding?

1. Very accurate
2. Great for autobody work
3. Very clean, no spatter 
4. No sparks
5. Favored by many experienced welders

TIG Welding Advantage Summary

TIG welding provides a solution for welding critical joints and when small or extremely precise welds are needed. It can be performed with a wide variety of metals, and when done correctly, it produces a high-quality, high-purity weld compared to other joining processes, which is crucial in many applications. Typically the price of TIG welders is very reasonably priced. Costs can differ, however, depending on the welded components and project scope.

What are the Disadvantages of TIG welding?

1. For more experienced welders
2. Higher learning curve
3. More limited

TIG Welding Disadvantage Summary

Although TIG welding can be performed with most metals, some metals are not weldable. Furthermore, TIG welding should only be carried out on clean metals, as the welding of dirty metals will result in weaker welding quality. And while TIG welding is known to produce the best quality welds, the process has a low deposition rate which means you can’t quickly weld stuff to TIG; there is a fixed speed at which TIG welding takes place. Similar to other welding types, it also takes a high degree of ability and dexterity to perform TIG welding.

SMAW welding

Top SMAW welders comparison Table

Welder	Image	Max Amps	Volts	Process	Prices
Hobart Handler 210		210	Dual	MIG/Flux	See Price 4.5/5
Hobart Ironman 230		250	220V	MIG/Flux	See Price 4.5/5
Lincoln Power MIG 210MP		220	Dual	MIG/Flux/ Stick/TIG	See Price 4.5/5
Hobart Handler 190		190	220V	MIG/Flux	See Price 4/5
Lincoln EasyMIG 180		180	220V	MIG/Flux	See Price 4.5/5
Miller Millermatic 211		230	Dual	MIG/Flux	See Price 4/5
Hobart Handler 140		140	110V	MIG/Flux	See Price 4/5
Forney 318 190		190	220V	MIG/Flux	See Price 4.5/5
Lincoln Easymig 140		140	110V	MIG/Flux	See Price 4.5/5
Everlast Poweri 140e		140	110V	MIG/Flux	See Price 4/5
Lincoln K2185-1		70	110V	MIG/Flux	See Price 4.5/5
Lotos MIG140		140	110V	MIG/Flux	See Price 3.5/5
Forney 309 140		140	110V	MIG/Flux79	See Price 3.5/5
Miller MIG Welder, Wheeled, 200 (208)/230VAC		300	Dual	MIG/Flux79	See Price 5/5

What is SMAW welding?

1. Shielded Metal Arc welding, commonly defined as manual arc welding, or flux shielded arc welding, is a method that utilizes a flux-coated electrode to shape the weld. When electricity passes through the electrode, the flux forms a gas that protects the electric arc in the gap between the metals being welded, preventing contamination from the environmental atmosphere around them. 
2. SMAW or Stick Welding remains one of the most widely used welding techniques used today, since it can be used both for repair welding and manufacturing that can be used on all ferrous metals in all welding positions.
3. This process is relatively simple and needs little in the way of specialized equipment which makes it very popular for all levels of users.

How does SMAW welding work?

• In SMAW the weld is created by a flux-coated electrode that is a metal stick or rod placed in an electrode holder connected to a power source. Electricity traverses the electrode and contacts the base metal.
• The flux, meanwhile, produces a gas that shields the electric arc between the electrode and the welded metal. It avoids pollution from ambient gasses, which makes SMAW welding ideal for outdoor work, unlike GMAW welding.
• Although SMAW is among the most common forms of welding techniques used, pulling off clean, solid SMAW welds takes expertise and preparation. 
• These problems are caused by welding process errors such as gas bubbles, using low voltage or high amperage, dirty metal, using too long a travel time, and or not allowing movement in welding and using improper metals. Pitfalls such as these demonstrate why proper preparation is so important. 
• SMAW also includes the removal of “slag,” a by-product coating that must be chipped off after the weld.

What can SMAW welding be used for?

1. SMAW welding will be used for a range of metal forms and various thicknesses, and is mostly used for heavy-duty work involving industrial iron and steel, such as carbon steel and cast iron, as well as low and high alloy steels and nickel alloys. 
2. SMAW is used in a number of industries, including: 
   1. Pipelines 
   2. Construction
   3. Manufacturing  
   4. Underwater Welding 
   5. Farming Machines 
3. One of the benefits of SMAW compared to other forms of welding is that the equipment is easily versatile and can be used in a range of settings, from indoor to outdoor to sea on a ship. And while SMAW is one of the oldest methods of welding, new technology is still evolving and increasingly making SMAW processes more effective.

What are the Advantages of SMAW welding?

1. Best for the value
2. Best for welds if you don’t care about how they look
3. Works well on dirty metals.
4. No onsite gas required.

SMAW Welding Advantage Summary

The machine used for welding purposes is not very costly, so everyone can afford it. It’s user friendly too. This makes it incredibly easy for people who would like to weld using ARC welding. Generally speaking, you’ll find welding equipment is unwieldy and heavy. The equipment used in ARC welding is compact which makes it very easy to use in all locations. It can be taken anywhere, and within a confined space, too. Auxiliary gas shielding isn’t required. The reason that it is most used is that it is suitable for welding most metals and alloys. So, you don’t need to go in for various welding forms because you can do with ARC welding.

What are the Disadvantages of SMAW welding?

1. For more experienced welders
2. Higher learning curve
3. More limited
4. Not as productive as continuous wire processes
5. Frequent stop/starts to change the electrode

SMAW Welding Disadvantage Summary

The electrode in ARC welding needs to be regularly replaced. Removing the slag from the weld is important. The welding operator should wear safety glasses and be very careful. The welder should also wear safety equipment in order to be protected from electrical discharge, burning and other issues that can occur due to the high temperatures. Welding is an essential method for joining two metals, and arc welding is most commonly used due to the minimal equipment required and a minimal training individual.

FCAW welding

Top FCAW welders comparison Table

Welder	Image	Max Amps	Volts	Process	Prices
Hobart Handler 210		210	Dual	MIG/Flux	See Price 4.5/5
Hobart Ironman 230		250	220V	MIG/Flux	See Price 4.5/5
Lincoln Power MIG 210MP		220	Dual	MIG/Flux/ Stick/TIG	See Price 4.5/5
Hobart Handler 190		190	220V	MIG/Flux	See Price 4/5
Lincoln EasyMIG 180		180	220V	MIG/Flux	See Price 4.5/5
Miller Millermatic 211		230	Dual	MIG/Flux	See Price 4/5
Hobart Handler 140		140	110V	MIG/Flux	See Price 4/5
Forney 318 190		190	220V	MIG/Flux	See Price 4.5/5
Lincoln Easymig 140		140	110V	MIG/Flux	See Price 4.5/5
Everlast Poweri 140e		140	110V	MIG/Flux	See Price 4/5
Lincoln K2185-1		70	110V	MIG/Flux	See Price 4.5/5
Lotos MIG140		140	110V	MIG/Flux	See Price 3.5/5
Forney 309 140		140	110V	MIG/Flux79	See Price 3.5/5
Miller MIG Welder, Wheeled, 200 (208)/230VAC		300	Dual	MIG/Flux79	See Price 5/5

What is FCAW welding?

• This is a very similar method to Metal Inert Gas Welding or simply called MIG welding. These processes use common equipment and continuous wire feeds.
• Flux-Cored Arc Welding uses a similar shielding gas to the MIG process. Yet Flux-Cored Arc Welding can also be operated without shielding gas. 
• This form of welding is moreover a much more efficient method than MIG welding. In our, and in many opinions,  FCAW is by far the most overlooked and yet efficient manual welding processes around. Yes, and you’re welcome to disagree.

How does FCAW welding work?

• During the Flux-Cored Arc Welding process, an electrical arc is used to unite a continuous metal electrode with the base metal. 
  • (Note: The MIG welding method uses a solid metal electrode while the FCAW process uses a flux-filled hollow tubular electrode.) 
• The flux-filled metal wire electrode automatically feeds through the middle of the gun using the same type of equipment used in MIG welding. 
• The gun-supplied gas shield protects the weld pool from oxidation throughout the welding cycle. 
• The flux within the electrode produces a slag which covers the weld and protects it from the environment. The shield provided by the flux allows for easier execution of the welding process outdoors, even in the heat.

What can FCAW welding be used for?

• Flux-core welding provides greater penetration, which is good for working with thicker joints. It also allows the welder to travel in all directions and to hold the torch in a number of directions. This makes it particularly suitable for general repairs, shipbuilding and other types of production. Flux-core welding does not require a high level of skill to execute. After a welder understands how to correctly set up the equipment, the method for proper welding is fairly simple and easy to learn. 
• Flow-core welding does not need to be used with a clean joint, as opposed to most welding practices. As long as moisture, paint, and oil are removed from the welding site, this type of welding may burn through rust, mill size, and other imperfections.

What are the Advantages of FCAW welding?

1. There are several arguments why flux core welding will be preferred to other welding methods. The following are just a few of them:
   1. It is very convenient for outdoor welding, or when you need to weld in windy conditions, as no shielding gas is required. 
   2. Since there’s no gas bottle around you, it’s very easy to move around while welding. In addition, it requires less equipment than other welding methods that allow you to move freely.
   3. When you have the correct filler metals like a consumable electrode, flux core welding is an all-position process.
   4. When other welding methods require extensive metal cleaning, the pre-cleaning requirement here is actually less than you think. But it’s still a good idea to clean up the metals at FCAW first as well.
   5. It is widely applied in the automotive industry because of its high-speed application capability. Think of it as the hot glue gun for welding.

FCAW Welding Advantage Summary

The machine used for welding purposes is not very costly, so everyone can afford it. It’s user friendly too. This makes it incredibly easy for people who would like to weld using ARC welding. Generally speaking, you’ll find welding equipment is unwieldy and heavy. The equipment used in ARC welding is compact which makes it very easy to use in all locations. It can be taken anywhere, and within a confined space, too. Auxiliary gas shielding isn’t required. The reason that it is most used is that it is suitable for welding most metals and alloys. So, you don’t need to go in for various welding forms because you can do with ARC welding.

What are the Disadvantages of FCAW welding?

1. Yields high quality, consistent welds with fewer defects
2. A high deposition rate, which is the speed that the filler metal is applied.
3. It can be used in all positions with the right filler metal.
4. Suitable for outdoor welding or shop welding.
5. Relatively easy to learn compared to other welding processes.
6. More forgiving of rust, scale, and other base metal contaminants.
7. The welding arc has good visibility.
8. It provides excellent weld penetration.
9. It allows for high welding productivity.

FCAW Welding Disadvantage Summary

The electrode in ARC welding needs to be regularly replaced. Removing the slag from the weld is important. The welding operator should wear safety glasses and be very careful. The welder should also wear safety equipment in order to be protected from electrical discharge, burning, and other issues that can occur due to the high temperatures. Welding is an essential method for joining two metals, and arc welding is most commonly used due to the minimal equipment required and a minimal training individual.