Posted on October-10-2025
If you’ve ever stood in a workshop and wondered which welding processes are best to use, you’re not alone. Even expert welders have strong opinions about which method is best. However the truth is that each type of welding process has its own strengths and weaknesses.
Let’s break down the four big ones: stick welding (SMAW), TIG (GTAW), MIG (GMAW) and flux-cored arc welding. Instead of just focusing on the basics we will cover what makes each process useful in a practical environment and what experienced welders like most.
Where it works best: Great for outdoor jobs where wind would blow away shielding gas. You’ll see it on pipelines, farm equipment, or quick field repairs.
What welders like about it: The gear is cheap and portable. You can throw a stick welder in the back of a truck and fix almost anything.
The catch: It’s messy. Lots of slag, lots of spatter. You’ll spend more time cleaning than with other processes.
Pro tip: Choosing the right electrode makes or breaks your weld. Beginners often default to iron-based rods, but if you’re working on stainless or cast iron, a specialty electrode will give you much better results.
TIG is slower and harder to learn, but it’s the method you reach for when appearance and precision matter most.
Where it works best: Thin metals, stainless steel, aluminium, and anything that demands a clean, smooth bead. Aerospace and automotive industries swear by it.
What welders like about it: Total control. You can create beautiful welds with minimal clean-up.
The catch: It’s not fast. TIG takes patience, a steady hand, and good torch discipline.
Common mistakes to avoid:
Rushing the weld (weak joints).
Using too much filler rod (creates porosity).
Forgetting to check your shielding gas (hello, contamination).
Fun fact: Many pros compare TIG welding to drawing with a fine-tip pen. If MIG is like spray painting, TIG is closer to calligraphy.
MIG welding is often the first process people learn because it’s fast, relatively easy, and versatile.
Where it works best: Fabrication shops, auto repair, and general metalwork. It’s quick, efficient, and great for production environments.
What welders like about it: Less skill needed compared to TIG, and the welds are strong enough for most everyday applications.
The catch: It doesn’t love the outdoors. Even a breeze can ruin your shielding gas coverage.
Insider tip: A well-maintained wire feeder is the secret to smooth MIG welding. Neglect it, and you’ll fight with inconsistent arcs and bird-nesting wires all day.
Think of FCAW as MIG’s tougher cousin. It uses a flux-filled wire instead of a solid one, which makes it better for certain heavy-duty jobs.
Where it works best: Structural steel, shipbuilding, and thick metal joints. Perfect when you need speed and penetration.
What welders like about it: It handles outdoor conditions better than MIG and delivers strong welds quickly.
The catch: It’s very messy, lots of spatter and slag. If you care about appearance, you’ll spend extra time grinding.
Pro tip: FCAW isn’t great for aluminium. Stick with carbon steels and heavy-duty alloys if you want consistent results.
There’s no one-size-fits-all answer. The best process depends on your project:
Stick – rugged, cheap, perfect for outdoor repairs.
TIG – slow but beautiful; the choice for precision and clean finishes.
MIG – fast, beginner-friendly, and reliable for most shop work.
FCAW – strong and efficient, ideal for heavy-duty or outdoor jobs.
Welding isn’t just about fusing metal, it’s about picking the right tool and process for the job. Next time you strike an arc, think about the trade-offs. Speed, cost, appearance, and environment all play a part in choosing the right method. The more you experiment, the more you’ll appreciate just how much art goes into this craft and the best solution for your job!
At Arc Welding we offer a range of new and used welding equipment from a range of manufacturers. Please contact us via telephone or our online contact form.
