No single welding process is best for every job; each suits different materials, thicknesses and working conditions. This comparison of MIG vs TIG vs stick welding explains where each process fits in sheet metal and structural fabrication, how to keep distortion under control, and what to put on your drawings so the fabricator welds exactly what you need.
MIG welding (gas metal arc welding, GMAW) feeds a continuous wire electrode through a gun under a shielding gas, usually carbon dioxide or an argon mix for steel. It is fast, consistent and well suited to production work.
TIG welding (gas tungsten arc welding, GTAW) uses a non-consumable tungsten electrode with argon shielding, and filler rod is added separately by hand. It is slower, but it gives fine control over heat and a neat, clean bead.
Stick welding (shielded metal arc welding, SMAW) uses a flux-coated electrode. The flux creates the shielding gas and leaves a slag layer over the weld. The equipment is simple and portable, and it copes with wind and less-than-perfect surfaces.
| Factor | MIG (GMAW) | TIG (GTAW) | Stick (SMAW) |
|---|---|---|---|
| Welding speed | High | Low | Medium |
| Heat control on thin sheet | Good with short-circuit transfer | Very good | Difficult; burn-through risk |
| Bead appearance | Good, some spatter | Very neat, no spatter | Rougher, slag to remove |
| Stainless steel | Suitable for non-cosmetic joints | Preferred for visible and hygienic joints | Used mainly on heavier sections |
| Outdoor or site work | Gas shield affected by wind | Gas shield affected by wind | Works well |
| Typical use | MS sheet metal, frames, batch production | SS cabinets, process equipment, thin aluminium | Structural steel, thick sections, repairs |
For mild steel sheet metal such as panel boxes, machine guards, trolleys and brackets, MIG welding is usually the most economical choice. Short-circuit transfer keeps heat input low enough for thin CRCA sheet, and the speed keeps labour cost down on batches. Stitch welds, short welds with gaps between them, are often used on long seams to limit heat and distortion.
TIG welding is chosen when the sheet is very thin, when a seam stays visible after painting or polishing, or when a joint must be leak-tight with minimal grinding. Stick welding is rarely used on thin sheet because the arc heat and slag make burn-through hard to avoid.
Galvanised (GI) sheet can be MIG welded, but the zinc coating burns off at the joint and gives off fumes. Good fume extraction is essential, and the weld zone needs touching up with zinc-rich paint afterwards to restore corrosion protection.
Stainless steel needs more care than mild steel. Too much heat causes discolouration (heat tint), distortion and, in some grades, reduced corrosion resistance next to the weld. TIG welding with a matching low-carbon filler, such as 308L for grade 304 and 316L for grade 316, is the usual choice for SS cabinets and process equipment.
MIG welding of stainless steel still has a place on thicker, hidden structural members of equipment, where speed matters more than appearance.
Machine bases, structural frames and racks built from channels, angles, pipes and hollow sections are commonly MIG welded in the workshop, where the gas shield is protected and output is high. Stick welding remains a sound choice for thick sections, joints with imperfect fit-up and site erection, where wind would blow the shielding gas away. Many jobs use both: MIG in the shop and stick for field joints. For frames built from rolled sections, see our channel, pipe and tube structures work.
For load-bearing structures, weld size should come from a design calculation, not habit. Oversized fillet welds add heat, distortion and cost without adding useful strength.
Every weld shrinks as it cools and pulls the parts with it. Distortion can be reduced but not removed, so it should be planned for at the design stage as well as on the shop floor.
A note saying "weld all round" leaves too much open to interpretation. A clear specification avoids disputes and rework:
If a joint has no weld symbol, the fabricator has to make a judgement. It is better to make that decision yourself at the design stage.
Vidhee Eng. Works carries out MIG, TIG and stick welding in-house at New GIDC, Kabilpore, Navsari, alongside laser cutting and press brake bending, under an ISO 9001:2015 certified quality management system. Our welding and fabrication work covers sheet metal enclosures, SS process equipment and structural frames, dispatched across India by road and available for export job work. Send us your drawing and we will suggest the process that fits your material and finish.
Send your drawing, material and quantity to Vidhee Eng. Works, Navsari, and get a clear quotation with a delivery date.
Both can weld thin sheet. MIG with short-circuit transfer is faster and usually more economical for mild steel enclosures and brackets made in batches. TIG gives finer heat control and a neater bead, so it is preferred for very thin sheet, stainless steel and seams that stay visible. Stick welding is generally unsuitable for thin sheet because of the burn-through risk.
TIG welding gives precise control of heat input, which limits discolouration, distortion and loss of corrosion resistance near the weld. It produces a clean bead without spatter, so less grinding is needed on visible surfaces. With a matching low-carbon filler and argon back purging where required, it is the usual choice for SS cabinets and process equipment.
Stick welding suits thick sections, structural steel and site work where wind would disturb the shielding gas used by MIG and TIG. The equipment is portable and copes better with surfaces that are not perfectly clean or joints with uneven fit-up. It is slower than MIG and leaves slag that must be removed, so it is less common for shop-made sheet metal parts.
Show weld symbols to ISO 2553 or AWS A2.4 with weld type, size, length, pitch and the side to be welded. Add material and filler grades, the required finish such as as-welded or ground flush, any post-weld treatment, and the inspection needed, such as visual checks, dye penetrant or leak testing. Clear information avoids rework and disputes.
Share your material, thickness and quantity — we’ll review it and come back with a quote and a delivery date, not just a price.
