Stick Welding vs MIG Welding: Which is Right For You?

Choosing the right tool for the job is something we all appreciate. However, picking the right welding process is just as important as selecting a tool for a welding project.

Picking the wrong welding process on a specific application can be like trying to saw through a 2×4 with a screwdriver; good luck with that.

As a novice welder, there are indeed many things to think about before you jump in and weld. Different metals will require application different materials or techniques and some methods are far more favorable to some applications than others.

How do you know which method is favorable to any application ? That is where this article comes to the rescue.

The three most common welding processes used in the world today are Stick and MIG. Each process has its advantages and limitations. Knowing which process to use will save you a lot of time and unnecessary grief.

In order to better help you know which process will suit you best in any given situation, you need to understand each process thoroughly. Let’s summarize each of these three processes so you can better pick which method is best suited for your application.

Stick Welding

If you have been welding for any length of time, you are probably familiar with welding with an arc welder. This type of welder uses a metal stick that is powered to create a very hot arc.

The process involves electric current flowing from a gap (the weld gap) between the welding stick, and the metal, to form metal joints.

In fact, stick welding has been the most popular and widely used form of welding for many decades. Stick welding is the type of welding for small, home-shop welders, and electricians. Stick welding is a useful way to weld most types of metal alloys or joints.

One advantage of the stick welder, is that it can be used both indoors and outdoors and in windy conditions, as well as in confined space. Stick welding is the most cost effective means of welding, and provides the ability to form effective metal joints, sometimes with rusty or dirty metals.

Stick welding does have some disadvantages as well. The size of the welding arc can generate enough heat to small metals. Stick welding is not effective on any metals thinner then 18 gauges.

In addition, with stick welding you will need to change the rod at a relatively fast pace. Stick welding uses a lot of spatter, and at the end of the welding process the weld usually needs to be cleaned.

For the novice, stick welding is also more difficult to learn and use. One of the most difficult tasks is striking and maintaining an arc, however after being able to strike an arc the process becomes easier.

Stick welders are available with an AC, DC, or AC/DC input. AC welders are the cheapest option, and are usually used for welding thicker metals 1/16 of an inch or greater.

Stick welders are most useful for farmers, to complete home repairs or DIY projects, and for permanent home projects such as fencing, and grill joints.

Advantages of Stick Welding

• Stick welding can be utilized for welding regardless of paint and corrosion at the welding location.
• You can attach a ground clamp that is located somewhere else on the metal to hold it in place far from the weld point.
• Stick welding creates a large arc that is unaffected by wind or temperature.
• Very easy to change or replace rods to weld ferrous and other special metals including cast metals, stainless, etc.
• Offers welding effectivity either inside or outside.
• Welders who are using the direct current (d/c) option can change the polarity of the electrode to help reduce the chances of a burn-through on thinner metals.

Disadvantages of Stick Welding

• Stick welding creates a deposit of slag on the metal after the joint is made. Before painting or welding again, the slag should be chiseled or scraped off the welds.
• There is also some spatter created during stick welding, although Direct Current (DC) stick welding has less spatter than Alternating Current (AC) welding.
• You will need to change the rod once in a while, which breaks the welding process.
• Stick welding is very hard to weld anything thinner than 1⁄8 inch.

MIG Welding (Metal Inert Gas)

MIG welders produce a wire welding electrode that feeds automatically from a spool through the welder at a constant speed. The electric current flowing between the base metal and wire ignites an arc.

This highly charged current melts the wire and the metal base, making a joint between them. The weld created from using this technology is quite durable and minimal cleaning is ever required.

MIG welding is considered to be more user-friendly and has a lot easier clean-up process once welding is complete. This process can be used on a vast array of both thin and thick metal plates. After about a week or two of welding, most people can master the basic MIG technique.

Two of the more difficult elements to MIG welding are selecting the correct shielding gas and setting the machine parameters.

Once you have taken care of these two items it is more or less just a “point and shoot” technique or a “hot glue gun of welding technique.”

It is possible to create high-strength welds that provide a good appearance and offer limited cleaning or sanding. The shielding gas allows the welder to create the arc at a constant pace, which makes the process incredibly easy.

MIG welders can also be used on all shapes of metal surfaces and are able to weld materials as thin as 26 gauge for finesse and accuracy.

MIG welding can contain some weaknesses. First off, equipment can be somewhat difficult to use if working outdoors as a result of the gases involved with welding.

You can work with all metals when you are using a MIG welder, however, a few materials have different spool wire and gas to accommodate those materials.

Additionally, someone working with a MIG machine must understand the various combinations that would be applicable to the project and set the machine up appropriately. This can be accomplished with machines that have auto-set features, as it can save you significantly.

You also must be sure to execute the MIG welding process from a clean metal surface to achieve a reliable outcome. Before laying down any welds, the welder must prep the surface of the workpiece and scrape away any paint, rust or any other debris from the surface.

Advantages of MIG Welding

• MIG welding is capable of being very accurate you can weld metal as thin as 24 gauge (0.0239″) with it.
• MIG welding is also quite clean, and you can make really neat, smooth, slag-free, and almost spatter-free welds.
• With MIG welding you do not have to stop your welding to refuel your stick rod, you only have to replace the spool that is used for welding.
• MIG welding is very easy to learn and easy to use. Even someone who is just starting out can become moderately good at MIG welding in a couple of weeks.
• MIG welding allows very good designs in welding that involve complex sections of welding.
• You can also achieve extremely quick welding speeds, and while this may be subject to interpretation, MIG welding is often considered to be the most productive.
• You can also apply MIG welding equipment for use on flux-cored welding jobs.

Disadvantages of MIG Welding

• Metal surfaces must be thoroughly cleaned. Even a small amount of rust, paint or contamination will create weak porous welds.
• If you are using ground clamps they must be securely clamped to bare metal and must be close to the welding point.
• Even a slight breeze or a fan can hinder the effectiveness of shielded gases resulting in porous weak welds.
• MIG welding use high pressured bottles of inert gas which will limit the potential for using it on the field.
• While you do not have to change the stick every now and then while welding, you must change the complete spool of wire when welding the different metals.

What’s The Difference Between MIG and Stick Welding?

MIG and Stick welding could both achieve a good weld but they are much different in their setups, pluses, minuses and applications. In general terms, MIG welding is the easiest type of welding to learn, and easiest torch to operate.

And while Stick welding can certainly be a quick learning curve, it is harder to become proficient. Stick welding is the oldest form of arc welding – dating back to the 1930s – and is still considered by some old-school, experienced welders as the only way to weld.

Quality And Quantity

Both MIG and Stick welding systems an produce very high-quality welds. However, the type of metal makes a big difference when it comes to which machine works better.

For thinner metals, MIG welding is superior for making a clean, strong joint. For thicker metals — over ⅜ inch — the Stick is superior.

Ease of use also allows the MIG gun to produce a lot of work and experience little downtime. Because of this, it is commonly used in fabrication, and a preferred process for robotics welding operations.

Stick welding requires a longer time to complete the weld process including a warm-up when first turning on the gun and experiencing more downtime for changing electrodes.

Cleanliness

Both MIG and Stick welders have completely opposite pros and cons regarding cleanliness and cleanup where one would have one or the other pre-weld, and one would have a post-weld.

A Stick welder could create a strong joint, typically on clean and rusty surfaces without any preparation of cleaning the workpiece that is required when preparing for MIG welding.

However, the electrodes that are used with stick welding are coated in flux which creates a spatter during the weld, and will have to be chipped off when cooled.

With MIG, not only does the shielding gas protect the weld while it cools but it blows off all the spatter, which is substantially less cleanup.

Versatility

One of the major benefits of Stick welding instead of MIG is that it will work in the wind, or outside in any conditions that might compromise the shielding gas of the MIG setup.

You can even wheel it out or place it exactly where you want it, while the MIG welder is constrained to the length of its cable. Another consideration for the Stick welder is that you can change the angle of the nozzle from straight, to bent to hook, allowing you to weld in tight places, corners and obtuse angles.

Maintenance And Cost

While stick welding is the least costly method of welding, MIG welding costs more than stick welding. This is due to the large number of consumables in MIG welding, and the considerable downtime and cost to replace consumables.

However, this cost might be offset by the long welds made possible by the MIG gun’s wire feed. A stick welder does not use consumables other than the electrode; but a weld can only be as long as the length of the stick before it needs to be replaced.

What’s Better? Stick Welding or MIG Welding?

There is no “best” choice. Each differ from each other and they both have their own place and purpose.

Stick welding is fantastic for fresh welders because it’s simple, and really cheap. You might not get the prettiest welds, but it will be strong, and if you don’t mind if the bead isn’t shiny, or don’t mind preparing the bead with cleaning and grinding, stick welding is adequate.

On the other end of the spectrum, MIG is quicker, easier, and cleaner. MIG welders have a prepare and learning curve, and are typically more expensive than stick.

A MIG welder is a better option for experienced hobbyist welders who weld often, or professional welders who might pick up side gigs.

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