Welding is a process of joining two or more pieces of metal together by melting and fusing them. There are many types of welding methods, but two of the most common ones are stick welding and MIG welding. In this blog post, we will explain what stick welding and MIG welding are, how they differ, and what are their advantages and disadvantages.
I. What is Stick Welding?
Stick welding, also known as shielded metal arc welding (SMAW), is a manual arc welding process that uses a consumable electrode covered in flux. The electrode is held in an electrode holder and connected to a power source that creates an electric arc between the electrode and the metal. The arc melts the electrode and the metal, forming a molten weld pool. The flux coating on the electrode burns and creates a gas shield that protects the weld from atmospheric contamination. The weld pool cools and solidifies, forming a strong joint. A layer of slag also forms on top of the weld, which needs to be chipped off after welding.
II. What is MIG Welding?
MIG welding, also known as metal inert gas (MIG) welding or gas metal arc welding (GMAW), is a semi-automatic or automatic arc welding process that uses a wire electrode and a shielding gas. The wire electrode is fed through a welding gun and connected to a power source that creates an electric arc between the wire and the metal. The arc melts the wire and the metal, forming a molten weld pool. The shielding gas, usually argon or a mixture of argon and carbon dioxide, flows through the welding gun and protects the weld from atmospheric contamination. The weld pool cools and solidifies, forming a smooth joint. No slag is produced in MIG welding.
III. How Do Stick Welding and MIG Welding Differ?
Stick welding and MIG welding differ in several aspects, such as:
Electrode: Stick welding uses a coated electrode that is consumed during welding, while MIG welding uses a wire electrode that is continuously fed during welding.
Shielding gas: Stick welding uses the flux coating on the electrode to create a shielding gas, while MIG welding uses a separate shielding gas tank to supply the gas.
Equipment: Stick welding requires simple and portable equipment, consisting of an electrode holder, a ground clamp, and a power source, while MIG welding requires more complex and bulky equipment, consisting of a welding gun, a wire feeder, a shielding gas tank, a gas regulator, and a power source.
Skill level: Stick welding is easier to learn and perform, as it only requires holding the electrode at a proper angle and distance from the metal, while MIG welding requires more skill and coordination, as it involves controlling the wire feed speed, the welding gun movement, and the shielding gas flow.
Weld quality: MIG welding produces higher-quality welds, as it has less spatter, porosity, and distortion, while stick welding produces lower-quality welds, as it has more spatter, slag, and defects.
IV. What are the Advantages and Disadvantages of Stick Welding and MIG Welding?
Both stick welding and MIG welding have their own advantages and disadvantages, depending on the type of metal, the thickness of the metal, the welding position, the welding environment, and the welding application. Some of the advantages and disadvantages are:
1) Stick welding advantages:
Stick welding is cheaper, more versatile, and more suitable for outdoor and windy conditions, as it can weld various metals, such as steel, stainless steel, cast iron, and aluminum, with different types of electrodes, and it does not require a shielding gas tank. Stick welding can also weld thicker metals and metals with some paint, rust, or dirt, as it has better penetration and tolerance.
2) Stick welding disadvantages:
Stick welding is slower, less efficient, and less clean, as it produces more slag, spatter, and smoke, which require post-weld cleaning. Stick welding also cannot weld thin metals, as it may burn through or warp them. Stick welding requires frequent electrode changes and slag removal, which interrupt the welding process.
3) MIG welding advantages:
MIG welding is faster, more efficient, and clean, as it produces less slag, spatter, and smoke, which require little or no post-weld cleaning. MIG welding can also weld thin metals and metals with complex shapes, as it has better control and precision. MIG welding produces smoother and more consistent welds, as it has a continuous wire feed and a stable arc.
4) MIG welding disadvantages:
MIG welding is more expensive, less versatile, and less suitable for outdoor and windy conditions, as it can only weld certain metals, such as steel, stainless steel, and aluminum, with specific types of wire electrodes, and it requires a shielding gas tank. MIG welding cannot weld metals with paint, rust, or dirt, as it may contaminate the weld. MIG welding also requires more skill and equipment, as it involves adjusting the wire feed speed, the welding gun movement, and the shielding gas flow.
A table of the comparison of Stick welding and MIG welding
| Welding Type | Stick Welding | MIG Welding |
| 1 | Uses a coated electrode that is consumed during welding | Uses a wire electrode that is continuously fed during welding |
| 2 | Uses the flux coating on the electrode to create a shielding gas | Uses a separate shielding gas tank to supply the gas |
| 3 | Requires simple and portable equipment | Requires more complex and bulky equipment |
| 4 | Easier to learn and perform | Requires more skill and coordination |
| 5 | Produces lower-quality welds with more slag, spatter, and defects | Produces higher-quality welds with less slag, spatter, and distortion |
| 6 | Cheaper, more versatile, and more suitable for outdoor and windy conditions | More expensive, less versatile, and less suitable for outdoor and windy conditions |
| 7 | Can weld various metals with different types of electrodes | Can only weld certain metals with specific types of wire electrodes |
| 8 | Can weld thicker metals and metals with some paint, rust, or dirt | Cannot weld thin metals and metals with paint, rust, or dirt |
| 9 | Slower, less efficient, and less clean | Faster, more efficient, and more clean |
| 10 | Requires frequent electrode changes and slag removal | Requires little or no post-weld cleaning |
V. Conclusion
Stick welding and MIG welding are two of the most common welding methods, but they have different characteristics, advantages, and disadvantages. The choice of welding method depends on the type of metal, the thickness of the metal, the welding position, the welding environment, and the welding application. In general, stick welding is cheaper, easier, and more versatile, but slower, less efficient, and less clean, while MIG welding is faster, more efficient, and more clean, but more expensive, more difficult, and less versatile.
