Stick weld vs. MIG: similarities and differences

You’re in the market for a new welder. You’ve heard a lot about MIG welders and stick welders, but you’re not sure which one is right for you.

In this article, we’ll compare the two most popular welding procedures and help you decide which one is best for you.

Introduction to welding 

Welding is the technique of melting two metal components together to join them.

There are many different ways to weld, but the most common methods are stick welding and MIG welding. Before you start any welding, make sure the metal surface is clean and rust-free.

Overview of stick and MIG weld 

When it comes to welding, you have several options: stick welding (also known as Shielded Metal Arc Welding, or SMAW), MIG welding (also known as gas metal arc welding, or GMAW), TIG welding, and flux-cored arc welding (FCAW).

Each of these has its benefits and drawbacks, so it’s important to understand the differences before you choose the right welding procedure for the job. 

Welding has become faster, easier, and more versatile with the invention of wire welding, which includes MIG and FCAW. Wire welding substitutes a spool of wire supplied by a welding cannon for the fixed-length stick electrode, which must be replaced regularly.

Stick welding is an electric arc welding process that creates the weld with a consumable electrode. Stick welding has several distinguishable advantages. It is incredibly versatile and can be employed to weld metal alloys like chrome, copper, and nickel, as well as ferrous metals like cast iron and steel. It is also suitable for welding thicker metals. 

This makes it an excellent option for heavier metals, and it is also quite portable. Stick welding is possible in the winds and even underwater. Stick welding is useful for repairing items that have a coat or rust somewhere at the welding point. To keep the metals away from the welding point, a floor clamp can be used.

MIG welding is a semi-automatic procedure that uses a flux-coated wire to weld metal alloys, like carbon steel, steel material, stainless steel, and alumina, but not cast iron. It works on both thin and thick metal plates. It can also be applied to flux-cored welding projects. 

It is more suitable for thinner metals and produces fewer droplets than stick welding. MIG welding is easier to learn than stick welding. When configuring MIG welding equipment, wire type, and size, gas, contact tips, and nozzles type must all be taken into account.

MIG machines, in contrast, are more complicated and expensive to set up and understand.

TIG welding is an autonomous procedure that creates welds with a tungsten electrode. As a result, it is ideal for minor welds and delicate tasks. 

Furthermore, apart from MIG welding, flux-cored arc welding does not necessitate the use of shielding gas.

Stick welding: process, benefits, and drawbacks

MIG welding receives all the attention. It is shiny, loud, and intimidating. Stick welding, in contrast, is an equally significant welding procedure. 

So, what exactly is stick welding? The weld is created using a consumable electrode in this technique. The electrode is a length of wire that has been coated in flux to protect the weld and ensure a robust weld. 

The benefits of stick welding are its versatility (it can be applied to a broad range of metals, from alumina to stainless steel) and ease of learning. The cons are that it can be slow, and requires more manual dexterity than some other welding processes.

But despite its disadvantages, stick welding is still an incredibly useful welding process and one that every welder should know how to use.

Metal Inert Gas welding: process, benefits, and drawbacks

MIG welding is a technique that is ideally suited for aluminum, mild steel, or stainless steel. It uses an electrode composed of non-consumable tungsten that is wrapped in a wire. A shielding gas is used to protect the electrode as it is welded to the specimen. It is effective on metals that are simply too shallow for stick welding.

Because stick welding produces spatter and slag, MIG welds are much more aesthetically pleasing. To ensure proper weld penetration when welding heavier metals with MIG, the load must be expanded and the surface must be free of paint and corrosion. 

When done correctly, stick welding generates deeper ties than MIG welding. MIG welding is indeed appropriate for flux-cored projects.

Pros of MIG welding include its higher speed, better accuracy, and greater flexibility when used on thinner metals. It also requires less skill and produces a good-looking weld that does not need additional cleanup once it has cooled down.

The biggest weakness of MIG welding is the cost of the equipment, which may be more expensive than stick welding because of the need for more special-purpose equipment and consumables.

Additionally, MIG welding takes more time to set up than other methods like stick or TIG welding. However, once you have the necessary pieces in place, this method can deliver high-quality results with very little effort compared to other types of welding processes.

Choosing the right method for your project

When you’re deciding between stick weld vs. MIG weld, it’s important to consider the project you’re doing. Stick welding is great for projects with thicker metals and materials, while MIG welding is ideal for thinner metals. But first, clean the metal surface where you’ll be working on. 

For instance, if you’re working on a car or truck body, you should opt for stick welding. This method delivers a strong weld because it uses higher voltage and heat to penetrate deeper into the metal. It also works well on rusty or contaminated surfaces and is great for outdoor applications.

On the other hand, if you’re working with more delicate materials like thinner metals or sheet metal, MIG welding would be your best bet. This method is much faster than stick welding and can be used on a variety of sizes and thicknesses of metal.

It also produces cleaner welds with minimal slag build-up and can be used for indoor or outdoor applications. It does require an additional shielding gas for effective coverage, though, so that is an additional cost to consider.

Tips for getting started with stick welding or MIG welding

If you’re planning to stick weld or MIG weld, then there are a few things that you need to know about the process.

Make sure that you have the right safety gear on hand and that your workspace is clean and organized. If you’re just getting started, then it’s best to practice in a safe area before tackling a large project.

The primary distinctions between stick and MIG welding

First, stick welding is great for outdoor applications because it can work in windy and wet conditions. This makes it perfect for maintaining existing infrastructure, like bridges. It’s also great for welding tough metals like cast iron.

In contrast, MIG welding produces a cleaner weld. It’s easier to control, too, making it perfect for beginners. And since the welder has more control over the arc, they can easily adjust the speed of welding to suit the job at hand.

That’s why it’s great for creating ornamental patterns or joining thin sheets of metal together without messily melting them into one another.

Advantages of stick welding

Stick welding is a common welding type where an electric arc is used to create the heat necessary to fuse metal parts. It’s easier to learn, requires less equipment, and can be used in a variety of positions, from flat and horizontal to vertical and overhead. Stick welds require no pre-cleaning or additional preparation work before application.

Advantages of using the Metal Inert Gas process

The MIG process is incredibly versatile and can be used on a variety of metals. One of the biggest advantages of using MIG is that it’s relatively fast and simple to use.

MIG produces a much cleaner-looking weld and is generally easier to learn than other welding processes.

Safety procedures for welding

Always remember to wear the proper safety gear such as gloves, a face shield, and overalls. Make sure that the work area is clean and free of debris before beginning any welding process.

Follow the manufacturer’s instructions on the proper operation of all equipment used in welding. Maintain safe distances from any heat sources when working with welding tools or materials.

Safety considerations for stick welding and MIG welding

With both stick welding and MIG welding, you should always wear appropriate safety gear. For stick welding, eye protection is important to protect your eyes from spatter. Gloves are also a must, as they’ll protect your hands from hot sparks.

Both techniques require ventilation when working indoors since the process produces gasses that can be dangerous if inhaled in excess.

Metals in use

When it comes to welding, you have two main options: stick welding and MIG welding. Stick welding involves melting two pieces of metal by melting and fusing them.

MIG welding involves using a wire feeder to feed a solid wire electrode into the weld joint. You then use a gun to create an electrical arc between the wire and the metals. This creates an arc that melts them and causes a chemical reaction that fuses the metals.

Applications

Stick and MIG welders are ideal for welding thin pieces of metal together because the heat is concentrated in a small area. This makes it easy to control the weld and produce a clean, consistent weld.

A stick welder’s heat is spread out over a larger area, so it’s not as precise as a MIG welder. But this means it’s less likely to cause warping or distortion during a weld.

Cost of operation

Talking about the cost of operation between stick and MIG welders, it comes down to which one suits your needs best. Stick welders tend to be cheaper than a MIG welder, but the tradeoff is that the process takes a bit longer and can be more difficult for those just starting.

MIG welding, on the other hand, is generally quicker and easier to do. And with faster welding, you can save time and money in the long run by getting your projects done faster. On top of that, you’ll also be using less equipment, meaning fewer expenses down the line.

So, in terms of the cost of operation, it depends on how often you plan to use your welder. If you’re only welding occasionally, then stick welding may be a better option because of its lower upfront cost.

But if you’re doing frequent welding jobs, then MIG may be the way to go since it’s faster, easier, and more cost-effective in the long run.

MIG and stick welders: indoor & outdoor use

Whether you’re welding indoors or outdoors, it’s important to choose the right welder for your needs. Stick welders are designed for both indoor and outdoor use and are suitable for most projects.

However, if you plan to do a lot of welding outdoors, stick welders might not be ideal due to their open-arc design.

On the other hand, MIG welders are better suited for outdoor use because they have a closed-arc design that makes them less prone to being affected by strong winds and dust.

Additionally, a MIG welder (or “hot glue gun”) has more settings than a stick welder, so it is better able to adjust the heat output depending on the application and materials being used.

What is the purpose of a stick welder? A Stick welder is effective for most alloys or joints and a stick welder may be used both inside and outdoors, as well as in drafty environments.

Stick welder welding is also the most cost-effective procedure and may form a strong bond on rusted or filthy metals.

MIG and stick welding: use of gas

The use of gas is one of the primary distinctions in both stick welding and MIG welding. Stick welding requires no shielding gas, whereas MIG welder requires an inert gas such as argon or carbon dioxide to avoid corrosion.

Additionally, a MIG welder may require a flux-cored wire that also requires shielding gas, whereas stick welding does not use flux-cored wire at all.

This means that MIG welders tend to be more expensive than stick welders because MIG welders require the additional cost of buying and maintaining a tank of shielding gas.

However, this cost can be offset by the higher quality welds that MIG welders produce and their ability to weld thicker materials than with a stick welder.

Similarities between MIG and stick welding

MIG and stick welding share some similarities. For one thing, they both involve melting electrodes with a welding power source and applying them in the right spots to join metals together.

Both processes also use an inert gas known as a shielding gas to protect the weld from the atmosphere. You can use either process on steel, aluminum, and stainless steel.

Additionally, you don’t need a lot of equipment for either one—you just need the welder unit itself and a few additional components like a ground clamp, electrode holders, and welding tips.

No matter whether you go with MIG or Stick welding, you’ll get clean welds that are structurally sound. The ultimate decision comes down to other factors such as cost, ease of use, portability, and speed of welding.

Conclusion

Ultimately, the method you choose depends on the metal you’re welding, the thickness of the metal, and your welding abilities.

With the right knowledge, you can make the right decision for the job at hand and get the job done right.

FAQs 

What exactly is MIG welding?

MIG welding is a type of welding that uses an electric arc to join two metal components together. The weld joint is continuously fed a wire electrode, and the arc softens the metal, forming a strong bond.

What exactly is stick welding?

Stick welding is a welding procedure where an electric arc is used to join two pieces of metal together. A stick electrode (a piece of metal that acts as the welding rod) is manually fed into the weld joint, and the arc melts the metal, creating a strong bond.

Is stick welding better than MIG?

Both MIG and stick welding devices can produce high-grade welding, but metals are the main factors in the way the machine functions. In thicker metals, MIG welding can be a safer option. The stick welder performs much better with thinner materials.

What is stick welding best for?

Stick welding is effective at welding all metals or joints, allowing indoor and outdoor usage or in damp places. Furthermore, it is the most economical technique that allows for good bonding with corroded metal.

What is the strongest type of weld?

TIG welds are considered to be the strongest welds because of the intense heat and the slow cooling speed. MIG welding also has the best possibility for the strongest types of joints because of its strong joint strength.

Read also: MIG welding titanium process: how to do it and factors to consider

Aron Russell

If you have come to my page, then you are trying to learn the correct technique for welding various parts. I can confidently say that you can trust me. I have been studying multiple welding techniques for 20 years. In my youth, I got a job at a factory, where my acquaintance with this technique began.

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