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Weve spent a lot of time discussing welding skills and technique in this magazine, but maybe its time to back up and start at the beginning: How do you decide what kind of welder to use in the first place?
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Sure, the skills and techniques weve covered apply to all types of welding, but weve generally assumed that our readers are most familiar with MIG welding. The MIG approach has become nearly ubiquitous thanks to the availability of relatively inexpensive, high-quality machines from numerous manufacturers.
However, more and more members of the grassroots community are getting their hands on TIG welders. A new wave of lower-cost equipment and a bevy of craigslist ads hawking used machines have given enthusiasts another affordable way to weld.
If you sit around and bench race welders with your friends, one of them will quickly proclaim that TIG is better than MIG. Is that true? Well, let us put forth this proposition: As with most of lifes big questions, the answer is, It depends. The two types of welders operate differently, and each one has its advantages and disadvantages. Well let you make the final call based on your needs.
When it comes to home welding, many people gravitate toward MIG units. A MIG welder uses a consumable wire that the machine feeds automatically. As a result, learning to use one is relatively easy.
Lets get right to it with some quick definitions. MIG stands for metal inert gas, while TIG stands for tungsten inert gas. Further, the M and T give us important information about each methods heat source. Lets dig into that subject next.
In the case of MIG welding, the heat source is the consumable wire. In the case of MIG welding, the heat source is the consumable wire. The wire and its arc heat the surrounding (base) metal, melting it together into a fused and welded joint.
With TIG welding, the heat source is the tungsten-tipped torch. The arc from the torch heats the surrounding metal, and then the consumable rod is melted in, forming the fused and welded joint.
Doesnt sound like these two welders are all that different, right? Turns out they really are: Where the heat comes from and, more importantly, where the heat goes, can significantly affect weld quality.
With MIG welding, the heat starts at the weld joint and moves to the base metal. With TIG welding, the heat starts at the base metal and moves to the weld joint.
Another big factor is how the weld cools. A MIG weld cools much faster than a TIG weld. Thats because the base metal surrounding it serves as a heat sink that quickly sucks the heat from the MIG joint. A TIG joint, on the other hand, cools relatively slowly because the base metal is already very hotand that means no heat sink effect.
A couple parts of this story will prompt the engineers to chime in with angry emails about our grassroots explanations of deeper science. Heres their first opportunity to do so: Time to discuss the strength differences between these two types of welds.
Most people understand that heat treating metal usually involves heating it and then cooling it, often rapidly. When metal is heat treated, it often becomes harder, which impliesand meansmore strength. This strength is often measured as tensile strength.
While high tensile strength is the real deal, it does have a couple side effects: increased brittleness and reduced malleability. Harder metal truly is strongerbut its only stronger until it breaks. Plus, sometimes brittleness is a bigger problem than low tensile strength.
Lets apply this to how MIG and TIG weld joints cool. It turns out that a MIG weld joint becomes very hard and very brittle due to its fast cooling. Conversely, a TIG joints slower cooling leaves it softer and more malleable.
A TIG unit doesnt take up much more space in the shop, but the welding process is a bit more involved. Prices for TIG machines have dropped to the point where more hobbyists are checking them out.
Theres more to these two types of welds than their strength and malleability. A large factor in the quality of a weld is the joints cleanliness, and this is another area where MIG and TIG welding are quite different.
Most people understand that the inert gas used in MIG and TIG welding plays a huge part in keeping the joint clean. However, theyre overlooking the role of heat.
Both machines circulate inert gasusually argon, CO2 or a mix of botharound the weld joint to keep it from becoming contaminated with dirty ambient air. This process works very well, but the gas shouldnt get all the credit. It turns out that heat can really help clean a weld joint, too, and thats where MIG offers an advantage.
Think about a self-cleaning oven. It works by running at a very high temperature, burning the crud off the racks and interior surfaces. The heat concentrated at the MIG joint has a similar effect on the base metal, improving the quality of the weld.
Youll remember that we strongly advocate cleaning weld joints thoroughly before welding. In fact, You cant weld dirt is one of our welding mantras.
While buying a MIG welder wont get you out of cleaning duties, sometimes its difficult to remove all of the grime. In these cases, MIG welding is your best bet. Maybe TIG isnt always better than MIG after all. See how it depends?
MIG and TIG welds feature different levels of hardnesstechnically called malleability. The piece on the left was TIG welded together before being passed through a planishing hammer at 10,000 blows per minute for about 2 minutes; the malleable weld was hammered nearly flat. The piece on the right was MIG welded together and also spent about 2 minutes in the planishing hammer. The hammer couldnt get very far since the weld was so much harder and therefore less malleable. (Its hard to see in the photo, but the brittle weld also cracked during the hammering. Hard can be good, but brittle can be problematic.)
Now lets go a little deeper into welding operation and theory. Engineers, heres your second chance to scoff at our generalizations or grab your pitchforks.
Weve talked about how heat affects the weld joint, and weve talked about where the heat is appliedat the joint or at the surrounding metal. It turns out that the polarity of the welder also affects where the heat ends up.
When welding steel, both MIG and TIG machines use DC current. There tends to be more heat on the positive side of an electrical circuit, and a MIG welders torch and wire typically handle that end of things; its ground wire is usually set to negative. This setup makes the MIG weld joint hotter and the base metal cooler.
A TIG welders polarity is the opposite. Its torch is set to negative and the ground is set to positive, which means heat travels into the base metal. Heres the rule of thumb: With a MIG weld, two-thirds of the heat is in the weld joint and one-third is in the base metal. With a TIG weld, the inverse is true: Two-thirds of the heat is in the base metal and one-third is in the weld joint.
Lets look at the TIG welding process a bit more. It uses DC current for steel, but it switches to AC current to tackle aluminum. Why the special treatment? Because aluminum is much more sensitive to contamination than steel. Its also much more likely to crack.
Aluminum requires a welding process that can handle dirt well (like MIG) and create a less brittle weld joint (like TIG). TIG welding with AC current offers a set of compromises that make it more suitable for the job.
Lets dive even deeper into the process. An AC circuit reverses polarity 60 times per second on common household or industrial current sources. They dont call it alternating current for nothing.
With TIG, the ideal setup for welding has the torch negatively charged and the base metal positively charged. The ideal setup for cleaning is when the polarity is reversed. Since AC current causes the polarity to switch constantly and rapidly, a single TIG welder can handle both the welding and cleaning processes. The result: a quality weld joint.
As a side note, more advanced TIG welders allow the user to adjust the AC process: You can lengthen the negative grounding wavelength to boost the cleaning capabilities, or lengthen the positive grounding wavelength for faster and more powerful welding.
So, what about welding aluminum with MIG? While it is becoming more common and practical to use specially equipped MIG welders for aluminum, TIG still tends to hold the advantage and is more flexible in most cases. This specific topic really warrants its own story, so keep your eyes peeled for that in a future GRM.
MIG and TIG machines both require the operator to use different techniques, but MIG welding is a bit easier. Once the knobs on the welder are properly set, welding with a MIG can be a one-handed affair. The on-off switch is located on the torch itself, and the welder automatically feeds the wire. (We recommend having two hands on the torch for additional control, though.)
If MIG welding is like throwing a ball, TIG welding is like juggling three of them. Guess which one is more difficult to master.
MIG welding can be a one-handed, point-and-shoot operation. You set the welder, pull the trigger, and off you go. With TIG welding, youve got to handle three different operations at once. One hand holds the torch and the other hand feeds the rod. Meanwhile, your foot is on the current pedal, and the harder you push, the more current (heat) you put into the weld.
As with juggling, these three factors must be in sync with one another or youll drop the ball and mess up the weld. So, this is another difference between MIG and TIG: It takes more time and practice to become proficient at TIG welding.
While that may make TIG seem less appealing, its complexity is actually a benefit. Good welding is about good control, and with a TIG welder you can dynamically control a lot more of the welding process.
With MIG, you set your current and wire speed before welding. After that, you dont have to worry about thembut you cant adjust them while you weld, either. TIG welding, on the other hand, allows you to make adjustments on the fly. If you need a little more heat, just press the pedal a little further. If you need a little less, back off a bit. More filler? Feed the rod faster. And so on.
TIG welders offer a level of flexibility that can greatly improve the quality of a weld. (Note: There are high-end MIG welders on the market that let you adjust these parameters as you go, but theyre generally out of reach for most enthusiasts.)
Another practical difference between these two welders involves prep work: MIG welding is more forgiving when it comes to the fit-up of the joint. Since TIG welding requires heating the base metal and then melting the rod, the base metal components need to fit together very tightly so they can be evenly heated and thus evenly melt the rod. If theres an air gap, the weld will often fail. On the other hand, since a MIG welders heat source is the filler wire, its not only more forgiving to the base metal, but it can also fill air gaps to some extent.
TIG welding is a bit more involved: One hand holds the torch, the other hand feeds the rod, and a foot controls the current. While harder to learn, the TIG process does offer the advantage of more dynamic control during weldingheat and speed can be easily adjusted on the fly.
Whether youre welding on the job or at home, time is usually money. MIG and TIG units operate at different paces, both before and during the welding process.
Assuming you have a higher-end MIG welder that can handle aluminum, converting it from its steel setting requires some work. Typically this means changing the shielding gas, the wire, the welder polarity (often with some disassembly of the welder) and even the liner or the whole welding torch assembly. Setting up a TIG welder for aluminum is usually as easy as flipping a switch from DC to AC and using a different rod.
However, MIG welding is typically a speedier operation than TIG welding. Since the wire feeds automatically and the heat gets in the weld joint faster, MIG welding is generally a timesaver.
We usually figure that MIG welding is about two to three times fasterthat is, it will take two to three times as long to lay a 12-inch bead with TIG than MIG. That extra time may not matter to everyone, but especially in production environments, MIG can offer a distinct advantage.
Finally, theres the cosmetic factor. Even the staunchest defenders of metal inert gas will admit that TIG welds look better than MIG welds. Sure, MIG welds can look nice, but TIG welds can approach art. That stacked-coins look produced by a well-executed TIG weld is what most welders are after, especially on exposed welds. Compared to the lumpier and less graceful look of the MIG weld, TIG work generally wins any beauty contest.
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So, is TIG better than MIG? Its certainly got some advantages, but so does MIG. We hate to say it, but the answer really depends. At least now you have the information to make the decision for yourself.
Which is the best for us? Hows this for an answer: Weve got both types in our shop, and we pick the best one for the operation at hand.
Welding is critical in many industries, yet choosing the right method can be challenging. With various options available, how do you decide which is best for your specific needs? This dilemma often leaves professionals and hobbyists questioning whether to opt for MIG (Metal Inert Gas) or TIG (Tungsten Inert Gas) welding.
This comprehensive guide is designed to demystify MIG and TIG welding techniques, providing clear insights into their fundamentals, advantages, and limitations. By the end of this article, you will thoroughly understand which welding method best suits your projects, ensuring optimal results and efficiency.
MIG and TIG welding may seem similar initially, but their procedures and applications differ significantly. Heres a detailed look at how each method works and what differentiates them.
MIG welding (Metal Inert Gas welding) is widely used for its speed and ease of use. This method involves feeding a continuous wire electrode through a welding gun while releasing a shielding gas. The weld pool is often shielded by CO2 (100%) or a mix of argon and carbon dioxide to prevent contamination from the air as the wire electrode melts and fuses the base materials.
One of the standout characteristics of MIG welding is its versatility. It can be applied to a wide range of metals, including steel and stainless steel, making it a dependable choice for many projects. The process is straightforward, making it accessible to beginners.
MIG welding is highly efficient for large projects requiring long, continuous welds, such as automotive repair, construction, and heavy equipment manufacturing. The continuous wire feed and automated process allow for faster welding speeds and higher productivity, instilling confidence in its applicability to diverse projects.
TIG welding, also known as Tungsten Inert Gas welding, is a technique that fuses metal using a non-consumable tungsten electrode. The TIG welder manually feeds a separate filler material into the weld pool while pure argon, an inert gas, shields the weld area from contamination. Due to its accuracy and control, TIG welding is ideal for precise and delicate work, providing reassurance about its suitability for such tasks.
A significant advantage of TIG welding is its ability to consistently produce high-quality, clean welds with minimal spatter. This makes it the preferred choice for critical appearance and precision applications, such as aerospace, piping, and artistic metalwork. The confidence in its performance is particularly high for projects where the appearance and integrity of the weld are critical.
Before you decide which welding technique to choose, understanding the pros and cons of TIG and MIG welding is essential. This knowledge guides your selection process and enhances your welding skills overall.
1. High Welding Speed and Productivity
The speed of MIG welding is a critical factor in high-volume production environments, such as automotive manufacturing. The continuous wire feed mechanism allows uninterrupted welding, minimizing downtime and increasing overall throughput. This efficiency is crucial for maintaining production schedules and reducing labor costs, making the MIG welding machine a preferred choice for large-scale industrial applications.
2. Versatility across Different Metals
MIG weldings ability to work with various metals makes it an essential tool in diverse industries. For example, in construction, the ability to weld steel beams for structural support and bronze for decorative elements using the same equipment simplifies the process and reduces the need for multiple welding setups.
1. High-Quality Welds
The precision of TIG welding makes it indispensable in industries where weld quality is paramount. For example, in aerospace engineering, the integrity of each weld must meet stringent safety standards. TIG welding provides the control needed to create flawless joints that can withstand extreme conditions, ensuring the reliability of critical components.
2. Suitable for Thin and Exotic Materials
TIG weldings ability to handle thin and exotic materials is a significant advantage in specialized fields. For instance, in the medical device industry, where titanium, magnesium, and other non-standard metals are often used due to their unique properties, TIG welding provides the precision required to create intricate, delicate welds without compromising the materials properties.
One of the primary differences between MIG and TIG welding is their equipment and setup. MIG welding uses a straight wire electrode provided through a welding gun and a protective gas to protect the weld pool from contaminants. This shielding gas is usually a mix of argon and carbon dioxide. The power source for MIG welding is a constant-voltage, direct-current (DC) machine, which keeps the arc stable and ensures consistent weld quality.
TIG welding generates the arc using a non-consumable tungsten electrode. As needed, the welder manually feeds a separate filler material into the weld pool. Pure argon is commonly used as the shielding gas, although helium or a mix of both can be used for specific applications. The power source for TIG welding can be alternating current (AC) or direct current (DC), depending on the material being welded. AC is often used for aluminum and magnesium, while DC is preferred for steel and other metals.
MIG and TIG welding are utilized in various applications, each suited to different project requirements. MIG welding is highly efficient for large-scale projects that demand high welding speeds, such as automotive manufacturing, construction, and heavy equipment production. The processs speed and ease of use make it ideal for tasks that require long, continuous welds.
TIG welding is chosen for applications where precision and weld quality are paramount. It is extensively used in aerospace, medical device manufacturing, and artistic metalwork. TIG weldings ability to produce clean, high-quality welds with minimal spatter makes it the preferred choice for projects where the appearance and integrity of the weld are critical.
The compatibility of welding methods with various materials is a significant factor in their selection. MIG welding is adaptable and can be used on various metals, including steel, stainless steel, cast iron, and bronze. This versatility makes it a go-to method for industries with different metals.
While versatile, TIG welding excels in thin materials like aluminum, copper, and nickel alloys and strange metals such as titanium and magnesium. The precise control over the welding process allows for detailed and delicate work without risking damage to the materials. This makes TIG welding indispensable in fields requiring meticulous attention to material properties and weld quality.
Speed and efficiency are critical considerations in industrial welding applications. MIG welding is known for its rapid welding speeds, making it highly efficient for large-scale production. The continuous wire feed mechanism ensures a steady supply of filler material, reducing downtime and increasing productivity. This makes MIG welding an excellent choice for projects with tight deadlines and high output demands.
TIG welding is slower due to the manual feeding of filler material and the need for greater precision. While this results in higher-quality welds, it also means that TIG welding is less suited for high-volume production. The slower pace of TIG welding is a trade-off for its superior control and quality, making it more appropriate for specialized projects where these factors are more critical than speed.
TIG welding is unmatched in weld quality and precision. The method allows for precise control over the heat and the welding process, resulting in clean, high-quality welds with minimal spatter. This is particularly important in aerospace and medical devices, where weld integrity is crucial.
While producing good-quality welds, MIG welding cannot match the precision of TIG welding. The process is more automated, and while this increases speed, it can also result in more spatter and less control over the weld pool. However, for many applications, especially those involving thicker materials, MIG welding provides adequate quality and is far more efficient in speed and productivity.
The skill level required for MIG and TIG welding varies significantly. MIG welding is generally more comfortable to learn and use, making it accessible to beginners and requiring less training. The automated nature of the process and the continuous wire feed system simplify the welding technique, allowing even novice welders to achieve consistent results relatively quickly.
TIG welding demands advanced skills due to the necessity of manually controlling the filler material and the tungsten electrode.TIG welding demands advanced skills due to the necessity of manually controlling the filler material and the tungsten electrode. To achieve high-quality results, the welder must have a steady hand and a good understanding of the welding process. This higher skill requirement means TIG welding often requires extensive training and practice.
Safety is a crucial aspect of any welding process, and both MIG and TIG welding have specific safety considerations. MIG welding involves shielding gases and a continuous wire feed, which can create hazards such as exposure to fumes and burns from the high heat generated by the welding process. Proper ventilation, protective clothing, and safety equipment are essential to mitigate these risks.
TIG welding also poses safety challenges, mainly due to the use of high-frequency current and the need for precise control of the welding arc. This process usually requires using both hands to manage the welding torch and filler rod, ensuring the welds precision and the operators safety. The dual-hand operation required for TIG welding, holding the torch in one hand and the filler rod in the other, demands a higher level of skill and coordination. Welders must wear appropriate protective gear, including gloves, helmets, and eye protection, to guard against burns and eye damage. Additionally, TIG weldings slower pace and the need for manual control increase the risk of fatigue, so it usually needs to use both hands during the welding process.
Its essential to note that the initial investment and operating costs for MIG and TIG welding can vary. MIG welding equipment tends to be more affordable and less complex, which makes it a more cost-effective option for many businesses. The continuous wire feed and shielding gas setup are relatively straightforward and cost-effective, with shielding gas prices typically ranging from about $20 to $150 per cylinder.
TIG welding equipment, on the other hand, can be more expensive due to the need for high-quality tungsten electrodes and more sophisticated power sources. Additionally, the process is slower, which can increase labor costs over time. The shielding gas for TIG welding can also be more expensive, typically ranging from $30 to $200 per cylinder. However, for applications where weld quality and precision are paramount, the higher costs of TIG welding can be justified by its superior results.
Selecting between MIG and TIG welding involves assessing technical aspects to determine the best fit for your project.
Due to its deep penetration capabilities, MIG welding is optimal for welding thicker materials. It works effectively on metals like steel, bronze, and stainless steel. TIG welding is competently suited for thin materials like aluminum and exotic metals. It provides precise heat control to prevent warping and achieve clean welds.
Industry-specific demands heavily influence the choice of welding method. MIG welding is preferred in industries requiring fast, large-scale production, such as automotive and construction. TIG welding is chosen in fields where precision and high-quality welds are critical, such as aerospace and medical device manufacturing.
MIG weldings high welding speed and continuous wire feed are advantageous for large projects needing quick completion. TIG welding, though slower, is ideal for projects requiring meticulous detail and superior weld quality, such as artistic metalwork or custom fabrication.
Operational costs differ between the two methods. MIG welding costs less due to faster welding speeds, less labor intensity, and the use of less expensive shielding gases. With its specialized equipment, slower process, and costly shielding gas, TIG welding can be more expensive, but it provides exceptional weld quality crucial for certain applications.
The versatility of MIG welding allows it to perform well in various positions, including flat, horizontal, vertical, and overhead. TIG welding requires more skill for out-of-position welds, necessitating careful consideration of the welding position when selecting the method.
Environmental conditions play a crucial role in welding method selection. External factors affect MIG welding less, and it can be used effectively outdoors or in less controlled environments. TIG welding, requiring precise control, is best suited for indoor settings where environmental conditions can be regulated to maintain weld quality.
Selecting the right welder for your needs is essential for achieving quality results and efficiency. Here are recommendations for Yeswelder MIG and TIG welders suitable for various applications, including industrial use.
The YesWelder MIG-205DS is a multi-process welder that supports MIG, flux core, and stick welding. Its synergic control mode simplifies setup and automatically changes the voltage and wire speed to ensure consistent weld quality. It is well-suited for various applications involving mild steel, bronze, and stainless steel.
The YesWelder YWT-200DC TIG welder supports both TIG and stick welding. It features a high-frequency start for smooth arc initiation and a digital display for precise adjustments. This model is ideal for tasks requiring detailed work on thin materials and exotic metals, providing excellent control and precision.
Designed for industrial applications, the YesWelder NBM-500 offers robust performance with advanced features such as pulse MIG and synergic control, enabling precise and high-quality welds. Its durable construction and high-duty cycle make it suitable for continuous operation in demanding environments like shipbuilding and structural steel fabrication.
The YesWelder TIG-315P is tailored for industrial-grade TIG welding and supports AC and DC operations. Its pulse welding capabilities allow superior control over heat input, making it perfect for high-precision tasks in aerospace and heavy equipment manufacturing. The advanced cooling system ensures reliable performance during extended welding sessions.
Selecting the appropriate welding method is crucial for achieving the desired results. MIG welding is ideal for large-scale projects requiring speed and versatility, while TIG welding excels in precision and high-quality work. The YesWelder MIG-205DS and YWT-200DC are excellent for versatile and detailed tasks. The YesWelder NBM-500 and TIG-315P offer robust performance and precision for industrial applications. Understanding the strengths of each welding method and matching them to your project needs ensures optimal outcomes and efficiency in your welding endeavors.
MIG welding involves a continuous wire feed and is better suited for thicker materials and high-volume projects. On the other hand, TIG welding utilizes a non-consumable tungsten electrode, providing precision and high-quality welds for thin and exotic materials.
Due to its speed and versatility, MIG welding is commonly used in automotive, construction, and heavy equipment manufacturing.
TIG welding provides superior control and precision, producing high-quality welds with minimal spatter, which is crucial for the aerospace industrys stringent safety and performance standards.
The YesWelder MIG-205DS features synergic control, which automatically adjusts the voltage and wire feed speed, ensuring consistent weld quality and simplifying welding.
The YesWelder TIG-315P supports AC and DC welding, includes pulse welding capabilities for precise heat control, and has an advanced cooling system, making it ideal for high-precision industrial applications. It operates within a welding current range of 20-315 amps and has a duty cycle of 60% at 40 over a 10-minute period.
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