What is the Difference Between Stick Welding and MIG? - TWI

MIG welding uses consumable electrodes that are delivered from a spool. Pulling the trigger on the spool gun feeds the wire at a preselected speed as a current passes through, melting both the electrode and the base metal.

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MIG welding is usually done with a DC (direct current) or reverse polarity, where the electrode is kept positively charged while the base metal is negatively charged. In either case, the base metal and the electrode melt together in a molten metal weld pool, which is protected from outside atmospheric contamination by a shielding gas. 

The equipment used by MIG welders is relatively simple and straightforward, with most MIG machines only using three settings for wire speed, polarity and voltage. The welding machine spool gun is also easy to use, with a trigger and an on/off switch.

There are a number of advantages with MIG welding, including:

• Precise: MIG welding offers a high level of precision, able to weld metal that is as thin as 24 gauge, as well as create intricate welding designs
• Clean: MIG welding is a clean process with little spatter, allowing for smooth, high quality, slag-free joins requiring minimal clean-up
• Efficient: Because it is a spooled wire welding process, there is no need to interrupt your welding work to replace the stick rod electrode
• Fast: MIG welding is one of the fastest welding methods, leading to high productivity
• Easy-to-Learn: MIG welding is easy to learn and the machines easy to operate, meaning that even a complete beginner can soon start to create acceptable welds
• Flux Core: MIG welding can also be used on flux cored welding projects

Despite the many advantages, there are also some disadvantages with MIG welding:

• Environment: MIG welding is difficult to perform outdoors as even a slight breeze can disrupt the shielding gas, leading to weak and porous welds
• Contamination: If the metal is contaminated at the weld point, it can lead to a porous weld, meaning that MIG welding is not ideal for metals with rust or paint on them. As a result, the metal surface must be completely cleaned before welding can commence
• Spool Changes: Although the wire spool means that there is rarely a need to change the electrode during welding, the spool will need changing when you weld different metals

MIG welding is a flexible technique that can be used for a range of metals and is easy to learn, allowing it to be used for a wide variety of applications.

Able to join both thin and thick metals, MIG welding can be used in different welding positions and with reactive metals like aluminum, copper, and magnesium, as well as stainless steel, carbon steel and nickel.

This versatility means that industries including oil and gas, power, automotive, construction, rail, marine, and more use MIG welding.

You can find out more about MIG welding here, but next we will examine stick welding.

Stick welding is an electric arc welding process that uses a metal stick or rod as filler material. These sticks are usually covered in a flux material and are available in different diameters and lengths. To achieve high strength welds, it is important to choose the correct type of flux core wire welding rod for your application.

Frequently used to weld steel and iron, stick welding uses a DC or reverse polarity current, as with MIG welding. This creates an arc between the welding rod or stick and the base metal. The heat of this arc melts both the base metal and the filler rod, droplets of which flow into the workpiece to form beads that fuse the two metal pieces together.

The heat also causes some of the flux to vaporise, creating a shielding gas that helps to stabilise the arc. The rest of the flux forms slag on the molten melt pool to protect the weld from contamination or oxidisation. The use of flux means that there is no need to use an external gas supply as with MIG welding.

The advantages of stick welding include:

• Environment: Stick welding creates a large arc that is not affected by wind, meaning that it can be used effectively both indoors and outdoors. Stick welding can be done in windy conditions and even underwater
• Paint and Corrosion Resistance: Stick welding can be used for repairing parts that have paint or corrosion at the welding point
• Easy-to-Learn: Stick welding is easy to learn, meaning that good quality welds can be made by someone with relatively little experience
• Changing Filler Material: It is easy to change filler material when you need to weld different metals such as cast iron or different stainless steels
• Reduce Burn-Through: By using the DC option for the arc, it is possible to alter the polarity of the electrode to reduce the possibility of burn-through when welding thinner metals
• Cost Effective: As there is no need for an inert gas supply, stick welding is an inexpensive option, as well as being easy to use in the field

While there are a number of advantages with stick welding, it also has its drawbacks:

• Slag: Stick welding deposits slag on the metal that needs to be scraped or chipped away before more welding or painting can commence
• Spatter: Stick welding produces spatter, although direct current (DC) welding produces less spatter than alternating current (AC) welding
• Welding Interruptions: There can be interruptions to your welding work when you need to replace the filler rod, which will reduce your productivity
• Welding Thinner Metals: Stick welding is not well suited to welding thinner metals of less than around 1/8&#; in thickness 

As stick welding doesn&#;t require a gas nozzle, it can be used to weld large materials as well as being able to be used both indoors and out, as the electrode flux prevents any contamination.

This means that stick welding is suitable for a wide range of applications, including large-scale construction, oil and gas pipelines and other outdoor jobs.

Because the weld surface doesn&#;t have to be completely free from rust or paint, stick welding is also well suited to repair and maintenance work.

You can find out more about stick welding here, but we will continue by comparing stick welding with MIG welding&#;

To fully determine the differences between MIG and stick welding, we will compare them over some key parameters:

1. Weld Quality

MIG welds tend to be of a better aesthetic quality than stick welds, since stick welding produces spatter and slag. However, by contrast, when welding thicker metals with MIG, the amperage needs to be turned up high and the surface needs to be completely free of paint and corrosion so as not to affect the weld penetration. When done correctly, stick welding produces stronger joins than MIG welding.

2. Indoor and Outdoor Applications

Because MIG welding involves the use of a shielding gas, it can only be performed indoors, as wind or rain can affect the weld. On the other hand, stick welding is wind and water resistant so can be performed outdoors or even underwater. However, the arc with stick welding can produce a lot of fume and smoke, which means good ventilation is required for the safety of the welder.

3. Metal Types and Thicknesses

MIG welding can be performed with different types of metal, so long as the surfaces are clean. MIG welds can be used for thin metals, including aluminium, brass, carbon steel, copper, magnesium, mild steel and stainless steel.  However, MIG welding is not ideal for thicker metals, unlike stick welding, which can fuse thicker metals. By contrast, stick welding is not as effective with thinner metals as it can cause burn-through.

4. Applications

MIG is a clean and fast process, making it suitable for a range of applications from small DIY projects to larger industrial welding tasks. However, MIG is unsuitable to outdoor or more extreme conditions as well as for welding thicker materials. In these instances, stick welding is the preferred option.

5. Ease of Use

Although stick welding isn&#;t a particularly difficult skill to learn, MIG welding is an easier technique to pick up. MIG welding allows you to operate one element at a time, pressing the trigger to automatically spool the wire and begin welding. Stick welding is slightly more difficult as you need to accurately strike the arc without damaging the weld metal.

6. Portability

Stick welding equipment is more portable than MIG welders, as it does not require an external shielding gas source.

7. Cost

MIG welding equipment is more expensive than stick welders, although when undertaken on an industrial scale, MIG welding becomes more cost-efficient due to factors such as improved productivity.

MIG welding is much easier for a beginner to learn than stick welding. However, setting up MIG welding equipment can be quite complex as there are a number of variables to consider, including wire size and type, gas, contact tips, and nozzle type. MIG welding also offers cleaner welds that require less post-weld cleaning.

Some argue that stick welding is stronger than MIG welding, since it offers better penetration for thicker materials.

However, MIG welding can provide good welds despite not being as effective on thicker metals, and is better for joining thinner metals with a good finish and less risk of burn-through.

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There are a number of key differences between MIG and stick welding, including the ease of the techniques, the thickness of the metals that can be readily joined, and the quality of the welds.

While MIG welding may be easier to learn, stick welding can be performed outdoors, even in adverse conditions. In addition, stick welding is not suited to welding thin materials while MIG welding is not suitable for thick welds.

Each type of welding process has its pros and cons when compared side-by-side, meaning that both are viable when the conditions and applications are suitable.

Related Frequently Asked Questions (FAQs)

Stick welding is a standard type of welding, which is also referred to as manual electrode welding, arc welding, and manual metal arc welding. It&#;s one of the first welding methods beginners learn during training, and it&#;s one of the most straightforward techniques that give new welders a solid idea of how the welding process works, various metal materials, and how to adjust the electrical voltage for each project.

SMAW or stick welding is performed with a rod electrode, which allows any type of weld to be created and is most commonly used in pipeline and steel construction. Manual metal arc welding is a traditional method of working with various metals and offers a lot of versatility. Stick welding doesn&#;t require shielding gases and is adaptable to different environments, including outdoor weather or temperature changes.

What Industries and Applications Is Stick Welding Used In?

Stick welding applications are widespread, as this welding technique is easy to learn and use in many settings. This versatile metal arc welding method is used across many projects and industries, including shipbuilding, construction, manufacturing, oil, structural welding, mining, and steel fabrication. Stick welding is widely used for standard repairs and manufacturing, as it&#;s a durable, cost-effective method for beginners and experienced welders.

One of the top features of stick welding is that it's portable and easy to set up quickly and effectively in various locations. It&#;s a convenient solution for on-site repairs in a warehouse, shop, and both commercial and residential environments.

Advantages of Stick Welding

Stick welding has many advantages, making it an excellent choice for many construction and repair projects. It&#;s one of the most versatile welding procedures that use quality welding equipment and is compatible with various electrodes and metals.

• Stick welding adapts to various materials, which is easy to adjust by changing the electrode while the remaining welding equipment remains in place. You can quickly change the electrode if you have several welding rods on hand, which makes the process simple and efficient.
• Stick welders do not require shielding gas since they produce their gas. Carbon dioxide is the most common shielding gas produced; you won&#;t have to provide shielding gas cylinders.
• Stick welding doesn&#;t require as much equipment as MIG welding and TIG welding. The main pieces required for a stick welding machine include a stinger lead and ground lead, with a box of various welding rods based on the type of metals you choose to weld.
• It&#;s low in noise and ideal for indoor spaces where sound can impact other people or neighboring businesses.
• Stick or shielded metal arc welding is portable, easy to handle, and used in almost any location. Since the electrode flux generates gas on its own, it&#;s one of the most preferred methods for welding on the go.
• Stick welding works well outdoors, even in windy conditions or rain.
• The cost of setting up stick welding equipment is affordable, as there is minimal equipment required.
• It&#;s easy to set up various tasks without extensive parts or requirements, such as shielded gas cylinders, hoses, or preparation familiar with laser welding, TIG, or MIG welding.

Stick welding is ideal for beginners, with minimal equipment, and is easily portable. It&#;s also widely used for various projects and doesn&#;t require advanced training to master. Gas metal arc welding is effective with most metals, such as base metal, stainless steel, carbon steel, and other common materials. It&#;s also robust and isn&#;t sensitive to oils, grease, rust, or similar residue.

Disadvantages of Stick Welding

While the stick welding application is easy, cost-effective, and adaptable to many settings, there are several drawbacks essential to consider. These disadvantages may have an impact on the project or construction performed, as specific welding machines are best suited for different tasks or repairs.

• Stick welding creates a lot of smoke, which can be unpleasant, mainly if used in a confined or narrow space.
• It&#;s a sturdy welding technique, though it&#;s typically slower than MIG or TIG welding, which is moderate to fast in efficiency. For this reason, stick welders are not preferred in some industries where high productivity is required.
• While many welding rods used with this method are moisture resistant, welding rods low in hydrogen, commonly used with arc welding, can be damaged if the atmosphere is damp.
• It&#;s a manual welding process, which means it can&#;t be automated, which would speed up the efficiency of this technique.
• There is a higher instance of errors, especially if welding is done in certain positions, and it may be challenging to work with thicker metals, which may require more planning and re-setting up the workstation.
• Stick welding often leaves debris and slag behind, a byproduct of the type of gas used from the electrode, which produces it to protect the arc. When slag forms, it must be removed by chipping with a hammer, chisel, or wire brush and sanding to create a smooth surface.
• Slag often left behind with stick welding may become a hazard and must be cleaned immediately to prevent further issues.
• It&#;s challenging to work with thinner metals, which is best for MIG or TIG welding methods.

While stick welding is highly adaptable for many projects and metal materials, large projects require numerous electrode replacements, which interrupts the job frequently. The manual arc welding process involves consumable electrodes, and you&#;ll likely need several on hand during a primary job or project due to the amount used. It&#;s also a dirtier welding method due to the residue and debris left behind, including lots of sparks, which increases the risk. Stick welding is an excellent option for new welders, though certain materials may require more experience and training to achieve good results.

Stick Welding for Beginners and Small Operations

It&#;s relatively easy to weld metal with stick welding equipment, though specialized materials and projects may require additional training and experience to create quality work. Fortunately, the supplies and equipment involved are user-friendly, and you can develop skills over time to improve the process and versatility of stick welding. One of the most critical aspects of shielded metal arc welding is maintaining consistency.

When an electrode becomes extremely hot, it&#;s essential to keep a steady distance between the arc and the metal to prevent a sudden voltage drop, also known as a &#;pop out,&#; which occurs when the electrode moves too far from the base metal. This situation may result in irregularities or inconsistencies in the weld, which should ideally be created without interruption for smooth, quality results.

While significant industries tend to choose highly productive welding machines, such as MIG welding, stick welding remains a top option for smaller manufacturing shops, portable repair applications, and similar operations and businesses.

Stick welding is the first type of welding technique introduced to beginners and the best way to start in this field. It&#;s also a highly effective way to build specialized objects and repair work without expensive equipment and time-consuming set-up of other techniques involving external shielding gas.

Where to Get Stick Welding Equipment

Sunbelt Rentals offer an impressive selection of welding equipment, whether you&#;re searching for stick welding supplies, electrodes, and related parts to build a versatile, productive workstation or provide all the welding equipment you need for an ongoing project.

While other modern welding styles are commonplace in many manufacturing facilities, construction sites, and workshops, stick welding is an excellent choice for cost-effectiveness and the ability to fit a variety of settings and conditions.

You&#;ll have the advantage of using state-of-the-art welding technology and high-standard equipment without significantly investing in welding machinery or facing supply issues due to growing demand.

When you consult our team of experts at Sunbelt Rentals, you&#;ll find lots of high-quality equipment for all your manufacturing and building needs. We offer an impressive inventory of plasma cutting equipment and all the supplies and materials you need for welding techniques for every type of weld.

Contact us to discuss your requirements of round stick machine. Our experienced sales team can help you identify the options that best suit your needs.