MIG VS TIG VS STICK WELDING: WHICH PROCESS DOES YOUR PROJECT ACTUALLY NEED?

Every welding job starts with the same question: what process should we use? If you’ve ever gotten quotes from different welders and noticed they mention different techniques — MIG, TIG, stick — you’re not alone in wondering what the difference actually is and why it matters for your project.

Here’s the short version: each process has strengths, and picking the wrong one means you’re either overpaying or getting a weld that won’t hold up. Let’s break it down in plain language.

MIG Welding: The Versatile Workhorse

MIG (Metal Inert Gas) welding — technically called GMAW — feeds a continuous wire electrode through a gun while shielding gas protects the weld from contamination. It’s fast, relatively easy to control, and produces clean results on mild steel, stainless steel, and aluminum.

When MIG Is the Right Call

• Fabrication projects — trailer frames, brackets, equipment mounts
• Automotive and equipment repairs — body panels, exhaust components, cracked frames
• Production work where speed matters and materials are consistent
• Thinner materials (16-gauge sheet metal up to about ½” plate)

MIG is our go-to for about 60% of the mobile welding jobs we run across Edmonton. It’s efficient, the equipment is portable, and the results are strong and clean. When you need a railing welded back together or a bracket fabricated on-site, MIG gets it done fast without sacrificing quality.

TIG Welding: Precision When It Counts

TIG (Tungsten Inert Gas) welding uses a non-consumable tungsten electrode and a separate filler rod. The welder controls heat with a foot pedal and feeds filler by hand. It’s slower, more demanding, and produces the cleanest, most precise welds of any arc process.

When TIG Is Worth the Extra Time

• Aluminum welding — bikes, boat components, aluminum railings
• Thin or delicate materials where heat control is critical
• Visible welds on decorative metalwork, furniture, or architectural features
• Stainless steel food-grade or sanitary applications
• Dissimilar metals or exotic alloys (chromoly, Inconel)

TIG costs more because it takes more time and more skill. But when you need a weld on a thin aluminum handrail that’s going to be visible every day, or a stainless steel component that has to look factory-finished, there’s no substitute.

Stick Welding: Tough Conditions, Reliable Results

Stick welding (SMAW) is the oldest arc welding process still in heavy use. It uses a consumable electrode coated in flux — no shielding gas bottle needed. That makes it the most portable and weather-resistant option available.

When Stick Makes Sense

• Outdoor structural work — fence posts, gates, heavy equipment
• Rusty, dirty, or painted metal that can’t be perfectly prepped
• Thick steel plate (¼” and up) where deep penetration matters
• Windy conditions — Edmonton’s gusts won’t blow away a shielding gas you’re not using
• Remote locations — acreages, farms, job sites with no power (with an engine-driven welder)

Stick welding isn’t pretty, but it’s incredibly strong and forgiving. For structural repairs on heavy steel in the field — especially in Alberta’s unpredictable weather — it’s often the smartest choice. We do a lot of stick welding on farm equipment repairs and structural posts around Edmonton and the surrounding area.

So Which One Do You Need?

Here’s a quick decision guide:

The reality is that many jobs use more than one process. We might stick-weld a structural repair for penetration, then cap it with a MIG pass for a cleaner finish. A good welder picks the process to match the joint, not the other way around.

Why Process Selection Matters for Your Wallet

Choosing the right welding process isn’t just about weld quality — it directly affects cost. TIG on a job that only needs MIG means you’re paying for extra hours you didn’t need. Stick on thin sheet metal means burn-through, rework, and frustration. When you call YEGWELD, we’ll recommend the right process for your specific project — no upselling, no overcomplicating it.

Got a project in Edmonton or within 100 km? Get in touch and tell us what you’re working with. We’ll let you know exactly what it needs.

This article is for informational purposes only and may contain inaccuracies. Always consult a certified welding professional before starting any project.