Quick answer: the four main arc welding processes are MIG (GMAW), TIG (GTAW), stick (SMAW) and flux-core (FCAW). MIG is the easiest to learn and fastest for fabrication. TIG gives the cleanest, most precise welds. Stick is the cheapest and best outdoors. Flux-core is like MIG without gas, so it works outside and on thicker or dirtier steel.
The 4 main welding processes compared
| MIG (GMAW) | TIG (GTAW) | Stick (SMAW) | Flux-core (FCAW) | |
|---|---|---|---|---|
| Electrode | Solid wire, fed by the gun | Non-consumable tungsten + separate filler rod | Flux-coated rod | Tubular wire with flux inside |
| Shielding | Argon/CO₂ gas | Argon gas | Flux coating (makes slag) | Flux (self-shielded) or flux + gas |
| Ease of learning | Easiest | Hardest | Medium | Easy |
| Speed | Fast | Slow | Medium | Fast |
| Thin metal | Good | Excellent | Poor | Fair |
| Thick metal | Good | Slow | Good | Excellent |
| Outdoors / wind | Poor | Poor | Excellent | Excellent (self-shielded) |
| Dirty or rusty metal | Poor | Very poor | Good | Fair |
| Clean-up | Little | None | Chip slag | Chip slag |
| Equipment cost | Medium | Medium–high | Low | Low–medium |
MIG welding (GMAW)
Gas metal arc welding feeds a solid wire electrode through a gun, while shielding gas (usually 75% argon / 25% CO₂ for steel) protects the weld. You pull the trigger and the machine feeds the wire.
- Best for: general fabrication, car bodies, sheet metal, home shop projects, production welding
- Metals: steel, stainless, and aluminium (with a spool gun and argon)
- Pros: easy to learn, fast, clean welds, little clean-up
- Cons: gas blows away outdoors; needs clean metal
Transfer modes: short-circuit (thin metal, all positions), spray (thick metal, flat and horizontal), and pulse (controlled heat). Controlled short-circuit processes such as STT welding refine short-circuit MIG for pipe roots and thin metal.
TIG welding (GTAW)
Gas tungsten arc welding uses a non-consumable tungsten electrode and a separate filler rod, under argon. You control heat with a foot pedal.
- Best for: stainless steel, aluminium, thin metal, pipe roots, motorsport, art and precision parts
- Pros: the highest-quality, cleanest welds; welds almost any metal
- Cons: slow, hardest to learn, needs very clean metal and calm air
Full guide: GTAW (TIG) welding explained. Machines: best TIG welders for beginners.
Stick welding (SMAW)
Shielded metal arc welding uses a flux-coated electrode (the “rod”). The flux burns to create shielding gas and a slag layer that protects the weld.
- Best for: farm and field repairs, structural steel, pipelines, maintenance, outdoor work
- Pros: cheapest equipment, works in wind, tolerates rust and paint (especially 6010 and 6011 rods)
- Cons: slag to chip, frequent rod changes, harder on thin metal
Machines: best stick welders for beginners.
Flux-core welding (FCAW)
Flux-cored arc welding uses a tubular wire filled with flux, fed like MIG.
- Self-shielded (FCAW-S): no gas needed. Popular with hobby 120 V welders and outdoors.
- Gas-shielded (FCAW-G): uses gas as well, for high deposition rates on thick structural steel.
- Pros: fast, deep penetration, works outdoors (self-shielded), good on thicker steel
- Cons: slag and more spatter and smoke than MIG
Other welding processes
| Process | What it is | Used for |
|---|---|---|
| Oxy-fuel (gas) welding | An oxygen-acetylene flame melts the metal | Thin steel, brazing, repairs, cutting (oxy-fuel cutting) |
| Submerged arc (SAW) | Arc buried under granular flux, usually automated | Thick plate, pressure vessels, pipe mills, shipbuilding |
| Resistance (spot) welding | Current and pressure through overlapping sheets | Car bodies, appliances |
| Plasma arc welding (PAW) | A constricted, focused arc, related to TIG | Precision and automated welding |
| Laser and electron beam | High-energy beams | High-precision, automated industry; handheld laser welders are increasingly common in fabrication shops |
| Friction stir | A rotating tool stirs the metal without melting it | Aluminium in aerospace, rail and marine |
Plastic pipe uses its own heat-fusion methods; see butt fusion welding.
Which welding process should you learn first?
- Building and fixing things at home: start with MIG or flux-core. They’re easiest to learn and the most versatile.
- Farm, fence and outdoor repairs: stick. It’s cheap, rugged and tolerant of dirty metal.
- Stainless steel, aluminium or show-quality welds: TIG, ideally after some MIG or stick experience.
- A welding career: learn stick and MIG/flux-core first (structural certifications), then TIG for pipe and specialist work.
Many modern multi-process welders do MIG, flux-core, stick and lift TIG in one machine, which is a good option for home shops.
Safety for every process
- Wear a proper welding helmet, safety glasses, and flame-resistant clothing.
- Ventilate. All processes produce fumes, and flux-core and stick produce the most.
- Keep flammables away and have a fire extinguisher nearby.
FAQ
What are the 4 types of welding?
MIG (GMAW), TIG (GTAW), stick (SMAW) and flux-core (FCAW).
What is the easiest type of welding to learn?
MIG welding (and self-shielded flux-core), because the machine feeds the wire and you only need to control the gun.
What is the strongest type of weld?
Weld strength depends more on the procedure, filler metal and the welder’s skill than the process itself. Stick, MIG, flux-core and TIG can all make welds as strong as the base metal.
Which welding is best for thick steel?
Flux-core, stick and spray-transfer MIG are all good for thick steel. In industry, submerged arc welding is used for very thick plate.
Which welding process is used for aluminium?
TIG (with AC) for precision work, and MIG with a spool or push-pull gun for faster work.
How this guide was written: process names follow American Welding Society (AWS) terminology. Related: types of welding joints. See how I test and review.