ARC vs MIG vs TIG: Which Welding Process to Choose
ARC, MIG and TIG all join metal with an electric arc. They differ in what fills the joint and what protects the hot weld from the air, and that decides which jobs each one suits. Here is a side-by-side comparison, then what each process needs, and quick picks by job.
At a glance
| ARC / MMA (stick) | MIG / CO2 | TIG | |
|---|---|---|---|
| Fills the joint with | A coated electrode (rod) | Wire fed from a spool | A filler rod added by hand, or none |
| Protects the weld with | The electrode's coating | Shielding gas (CO2 or a mix), or flux-cored wire | Argon gas |
| Best on | Mild steel, structures, repairs | Mild steel fabrication, long welds | Thin sheet, stainless steel, neat visible welds |
| Metal thickness | About 2.5 mm and up | About 1 mm and up | Thin to medium, even under 1 mm |
| Speed | Medium: you stop to change rods and chip slag | Fastest | Slowest |
| Outdoors and wind | Good | Poor with gas; good with gasless wire | Poor |
| Easy to learn | Moderate | Easiest | Hardest |
ARC / MMA (stick)
The everyday process in most workshops. A machine, a holder and a packet of rods is all it takes, and it copes with rust, paint and wind better than the others, so it suits gates and grills, structures, repairs and site work. The trade-off: it is slower, you chip the slag off every run, and sheet thinner than about 2 mm is hard to weld neatly.
You'll need: an ARC welding machine, an electrode holder and earth clamp, welding rods to suit your machine's current, and a welding helmet and gloves.
MIG / CO2 (MIG/MAG)
Wire feeds through the torch while gas shields the weld, so you can weld long seams without stopping, with little cleaning afterwards. It is the fastest process and the easiest to learn, which makes it the choice for fabrication shops making frames, furniture, racks and enclosures. Wind blows the gas away, so for outdoor work use gasless flux-cored wire instead.
You'll need: a MIG welding machine (with a built-in or separate wire feeder), MIG wire, a CO2 cylinder and a CO2 regulator. For long, continuous welding choose a regulator with a heater, because CO2 cools as it flows.
TIG
TIG gives the cleanest, most precise welds, with no spatter. A tungsten electrode makes the arc and you add filler rod by hand. It is the process for stainless steel, kitchen and food equipment, thin sheet and pipe where the weld must look good, and, with an AC/DC machine, for aluminium. It is slower and takes the most practice.
You'll need: a TIG welding machine (AC/DC for aluminium), an argon cylinder (ask us), an argon flow meter, tungsten electrodes and filler rods for your metal. Many TIG machines also weld ARC, so one machine covers both.
One machine for more than one process
Multi-process machines, such as MIG, lift TIG and ARC in one, suit workshops with mixed jobs: one machine instead of two. See our welding machines, or ask us which one fits your work.
Quick picks by job
- Gates, grills, structures and site repairs: ARC.
- Workshop fabrication with a lot of welding (frames, racks, furniture): MIG.
- Stainless steel, kitchen equipment, thin sheet, aluminium: TIG.
- Mixed jobs: a multi-process machine, or ARC and TIG in one.
Safety for every process
- Wear a welding helmet with the right shade, leather gloves and long cotton sleeves: arc light burns skin and eyes.
- Weld with good ventilation, and keep anything that can burn well away from sparks.
- Keep the work clamp tight, and your hands and gloves dry.
Not sure? Tell us the metal, its thickness and the job on WhatsApp, or try the welding machine finder.
General guidance only. Always follow the manufacturer's instructions for your machine, gas and electrodes.