4 Types of Welding Explained: MIG vs TIG vs Stick vs Flux Core

Summary

This video provides a clear, high-level overview of the four most common welding processes: stick, flux core, MIG, and TIG welding. It explains how each process works, the equipment required, their advantages, limitations, and ideal applications—from structural repairs to precision aluminum work. The instructor highlights practical considerations such as portability, cost, and ease of learning, and also touches on multi-process machines that combine capabilities. Viewers gain a solid understanding of which welding method may suit their needs, whether for general-purpose projects, auto body work, or precise, controlled welding tasks.

Takeaways

• 🔥 Stick welding uses a rod with a flux coating to create an arc, melting both the rod and base metal while protecting the weld from contamination.
• 💰 Stick welding is inexpensive and portable, making it ideal for thick materials, structural projects, and general repairs.
• 🛠️ Stick welding leaves slag on the weld that must be chipped away, and it is challenging for thin metals below 1/16 inch.
• ⚡ Flux core welding operates similarly to stick welding but uses a wire with flux fed through a motorized gun, simplifying the process.
• 🎯 Flux core welding is easier to learn, allows continuous feed, and works for thin to medium-thick materials, but still produces slag.
• 💨 MIG welding feeds wire through a gun with shielding gas to prevent contamination, producing clean, slag-free welds.
• 🚗 MIG welding is fast, precise, ideal for thin sheet metal and auto body work, but requires a gas cylinder and higher equipment cost.
• 🖋️ TIG welding uses a non-consumable tungsten electrode with separate filler metal, offering high precision and control for delicate work.
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• 🌟 TIG welding is ideal for aluminum (requires AC output) and allows stick welding with the same machine, but is harder to learn and more expensive.
• 🔄 Multi-process machines can perform MIG, TIG, Stick, and sometimes Flux Core, providing versatility but may have limitations for TIG (e.g., AC output, arc start).
• 🛡️ Proper shielding and gas types are critical for MIG and TIG welding; multi-process machines may require separate gas cylinders for each process.
• 📈 Beginners can start with basic machines for stick or flux core welding and upgrade to MIG/TIG setups as needed for more advanced work.

Q & A

What is stick welding and what are its alternative names?

Stick welding, also called shielded metal arc welding (SMAW), manual metal arc welding (MMAW), or rod welding, uses a consumable electrode rod with flux coating to create an arc that melts both the rod and the base metal.

How does stick welding protect the molten metal from contamination?

The flux coating on the electrode burns off during welding, producing gases that shield the molten metal from oxygen and other contaminants in the air, and leaves a slag coating on the weld.

What are the main advantages and limitations of stick welding?

Advantages: inexpensive equipment, portable, effective for thick metals, good for structural projects and outdoor work. Limitations: leaves slag, challenging for thin sheet metal (less than 1/16 inch or 1.5 mm).

How does flux core welding differ from stick welding?

Flux core welding uses a continuous wire with flux inside, automatically fed through a gun. It creates an arc similarly to stick welding but is easier to learn and maintains a continuous feed without stopping to replace electrodes.

What are the benefits and drawbacks of flux core welding?

Benefits: easier to learn, continuous wire feed, can weld thin to moderately thick metals, relatively inexpensive. Drawbacks: still produces slag that needs to be removed.

What makes MIG welding different from flux core welding?

MIG welding uses a wire electrode and a shielding gas instead of flux, producing clean welds without slag. It is faster and works well for thin to moderately thick metals, including auto body work.

What are the limitations of MIG welding?

MIG welding equipment is more expensive and less portable due to the need for a shielding gas cylinder.

How does TIG welding work and what makes it precise?

TIG welding uses a non-consumable tungsten electrode to create the arc, and filler metal is added separately. This decoupling of heat and filler allows for fine control and precision, ideal for detailed work and aluminum.

What are the main advantages and challenges of TIG welding?

Advantages: most precise welding process, ideal for aluminum and thin materials, excellent control. Challenges: most difficult to learn, requires expensive equipment, less portable.

What are multi-process welding machines and what should be considered when using them?

Multi-process machines can perform stick, MIG, TIG, and flux core welding. Considerations: TIG function may be limited (arc start type, AC/DC output), and MIG/TIG require different shielding gases, which increases cost.

Which welding processes are best for beginners and why?

Stick and flux core welding are best for beginners due to their simpler equipment, lower cost, and easier learning curve.

For what type of projects is stick welding particularly well suited?

Stick welding is ideal for structural projects, repairs, pipelines, furniture, trailers, and outdoor work where thick metals are involved.

Why is shielding gas used in MIG and TIG welding?

Shielding gas protects the molten weld pool from atmospheric contamination (oxygen, nitrogen), preventing defects and eliminating the need for slag.

Why might someone choose TIG welding over MIG or flux core welding?

TIG welding is chosen for precision work, high-quality welds, and when welding metals like aluminum that require controlled heat and filler placement.