MIG vs. TIG vs. Stick Welding — Which Fits Your Project?

The “right” process depends on base metal, thickness, environment (shop vs. field), required finish, and schedule. Use this guide to decide—or send photos/specs and we’ll recommend the procedure and inspection plan.

Quick Comparison

Process Best For Finish Quality Speed Typical Materials Common Use-Cases
MIG (GMAW) Production & structural Good Fast Carbon steel, stainless, aluminum (proper setup) Frames, stairs, rails, shop fabrication
TIG (GTAW) Precision & show surfaces Excellent Moderate–Slow Stainless & aluminum (thin–medium), specialty alloys Restaurant/brewery stainless, architectural details
Stick (SMAW) Outdoor & repair (thicker steel) Fair–Good Moderate Carbon steel (medium–thick sections) Field repairs, heavy equipment, structural retrofits
MIG welding on structural frame

MIG Welding (GMAW)

  • Pros: High deposition and speed; consistent beads; efficient for repetitive structural work.
  • Cons: Spatter and cleanup on show surfaces; shielding gas limits outdoor use without protection.
  • Best Use: Frames, stairs, guardrails, shop fabrication.
  • Link: See our Structural Steel Welding.
TIG welding precision bead on stainless

TIG Welding (GTAW)

  • Pros: Extremely clean, precise welds—ideal for stainless and aluminum; excellent for visible work.
  • Cons: Slower, higher labor cost; requires clean prep and tight fit-up.
  • Best Use: Restaurant/brewery stainless, architectural details, thin materials.
  • Link: Related scopes in Process Piping Fabrication.
Stick welding field repair on heavy steel

Stick Welding (SMAW)

  • Pros: Excellent outdoors; tolerant of dirty/rusted steel; great for thicker sections and repairs.
  • Cons: Slag removal and more cleanup; not for thin cosmetic work.
  • Best Use: Field repairs, equipment, structural retrofits, gates/fences.
  • Link: Book Mobile & Emergency Welding.

How We Choose (What Actually Drives the Call)

  • Material & Thickness: Thin stainless/aluminum → TIG. Mid-thickness carbon steel → MIG. Heavy/outdoor → Stick.
  • Environment: Shop favors MIG/TIG; wind/rain favors Stick.
  • Finish: Architectural or sanitary → TIG. Hidden structural → MIG/Stick.
  • Schedule/Budget: Fast turnaround → MIG; premium aesthetics → TIG; rugged repair → Stick.
  • Inspection/Docs: We can support WPS/PQR/WPQR and coordinate inspections as required.

Explore related scopes: Structural Steel • Process Piping.

Common Austin Project Cases

  • Commercial stairs & rails: MIG for structure; TIG on any visible stainless caps or details.
  • Restaurants & breweries: TIG for sanitary stainless and clean, polishable beads.
  • Emergency field repairs: Stick for speed and reliability in the elements.
  • Architectural features: TIG for minimal cleanup and show-quality appearance.

Need us on-site? Mobile & Emergency Welding.

60-Second Decision Checklist

  • Base metals & thicknesses (steel/stainless/aluminum; thin vs. thick)?
  • Is the weld visible (architectural/sanitary) or hidden (structural)?
  • Shop vs. field? Any wind/contamination risks?
  • Timeline & budget (speed → MIG; premium finish → TIG)?
  • Any inspection/code requirements (WPS/PQR/testing)?
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