Walk into any workshop and you can tell straight away who knows their gear. They pick up a torch, adjust a setting or two, and the weld flows as if the metal wanted to join in the first place. That level of comfort only comes from understanding the tools, not just owning them.

I’ve met plenty of people who want to get into welding but feel lost the moment they see how many machines exist. MIG, TIG, Stick, Flux Core… it can feel like someone handed you a toolbox without telling you what anything does. Even experienced tradespeople sometimes buy a welder that looks right on paper, only to realise later that it fights them on half the jobs they do.

This guide clears that fog. Whether you earn a living on the tools or pick them up at the weekend, getting familiar with the different types of welders is the quickest way to better results. Once you grasp what each process handles well, you stop guessing. You start choosing the right method for the metal, the joint, the thickness, and the conditions you are working in.

Why Understanding Different Types of Welding Matters

Every welding process has its own behaviour. Some feel smooth and steady, almost like drawing with a marker. Others bite into thick steel with a punch of heat that you can feel through your gloves. The wrong choice can turn a simple job into a frustrating one, and the right choice can take the stress out of the whole process.

A few examples tell the story. Try using gas-shielded MIG outdoors on a windy afternoon and the weld will blow out before it forms properly. Use Stick on thin material and you can watch the metal melt away faster than you can react. Switch to TIG for detailed work on stainless and you suddenly see how clean and neat a weld can look when the process matches the task.

Choosing the right method also keeps your time, money, and patience intact. A tradesperson cannot afford wasted hours or constant rework. A DIY user does not want to spend half a weekend fighting the tool instead of getting the project finished. The right process for the material and the situation avoids that.

Skill level plays a part too. Some methods are friendly to beginners. Others reward a steady hand and a bit of practice. There is nothing wrong with starting simple, as long as you know what that simplicity gives you and where its limits sit.

When you understand the types of welders, everything falls into place. Your welds improve. Your confidence grows. You know what to expect before you strike an arc, and that makes the whole job smoother.

Types of Welders

Gas Metal Arc Welding (GMAW) – MIG Welding

MIG is usually the first process people try, and there is a good reason for that. It feels straightforward, it is quick to set up, and it handles a wide range of everyday jobs.

Instead of juggling rods, filler wire and shielding at the same time, you simply pull the trigger and the wire feeds through. Once you get the hang of the settings, it becomes a very comfortable way to weld.

Applications

MIG is common in automotive repair, metal fabrication, light manufacturing, household projects and general workshop tasks. It handles medium-thickness steel nicely and is handy when you want clean weld aesthetics without spending all day setting up.

Many mechanics use MIG for body panels because the control and speed suit thin steel, provided the technique is right.

Gas Tungsten Arc Welding (GTAW) – TIG Welding

TIG is the method people turn to when they want precision. It is slower and demands more coordination, but the level of control feels unmatched once you get used to it.

A torch in one hand, filler rod in the other, and your foot controlling the amperage: it is as close as welding gets to fine craftsmanship.

Applications

TIG is heavily used in aerospace, motorsport, stainless steel fabrication, medical equipment, custom aluminium work and any project where the weld needs to look as good as it performs. It is the method fabricators choose when neatness, tight control and weld quality are the top priorities.

Shielded Metal Arc Welding (SMAW) – Stick/MMA Welding

Stick welding has been around for decades and has earned its place on every building site and farm in the country. It is tough, reliable and not fussy about the conditions.

Many tradespeople keep a Stick welder in the van simply because they know it will work whether the metal is clean or covered in years of grime.

Applications

Stick welding is widely used in construction, shipyards, farming repairs, heavy steel fabrication and pipelines. It is the method most tradespeople trust when working outdoors or when the steel is too dirty for MIG or TIG. If you need something strong and reliable on thick material, Stick rarely disappoints.

Flux-Cored Arc Welding (FCAW)

Flux-cored welding looks very similar to MIG at first glance, but the wire itself carries the flux inside. This makes a big difference in real conditions. It handles wind, digs deep into thick steel and puts down a weld with serious penetration.

It is a favourite for structural work, repairs on heavy machinery and any job where strength matters more than appearance.

Applications

Flux-core is common in construction, shipbuilding, heavy equipment repair and large steel projects where speed and penetration matter. It shines on anything from structural beams to agricultural equipment. If you need strength on thick material and want something more efficient than Stick, flux-cored wire is a solid choice.

Specialised and Complementary Welding Methods

Some welding processes sit outside the typical MIG, TIG, Stick and flux-core setup. You may not use them every day unless you work in heavy industry or precision fabrication, but they are worth knowing about. Each one fills a gap that the standard machines cannot reach.

1. Plasma Arc Welding (PAW)

Plasma welding feels like TIG taken to another level. The arc is forced through a narrow nozzle, which turns it into a tight, high-energy jet. It gives incredible control and produces smooth, strong welds with very little distortion. Anyone who works with fine stainless, aerospace components or medical equipment will be familiar with it.

PAW can look intimidating at first sight, but once you see it in action, it is easy to understand why certain industries rely on it. The accuracy is remarkable and the heat stays focused exactly where you want it. It can also be used for plasma cutting, which is one reason some fabricators combine both skills.

2. Submerged Arc Welding (SAW)

SAW is a completely different approach to welding. Instead of watching a bright arc, the weld is hidden under a layer of granular flux. The flux melts and forms a protective cover over the pool, so there is almost no visible light, no spatter and very stable heat.

It is not something you set up in a small garage. SAW equipment is large, and the process suits heavy plate, long seams and repetitive industrial work. Shipbuilding yards, beam manufacturers and bridge fabricators rely on it because it produces deep penetration and a very consistent weld deposit. Once the machine is set correctly, it will run long passes that would be exhausting to repeat manually.

3. Oxy-acetylene Welding

Oxy-acetylene is the old faithful of metalwork. Long before inverter welders became common, people used a gas torch for everything from cutting to brazing to full fusion welding. It is a simple setup: oxygen and acetylene mixed through a torch to create a very hot flame.

While electric welding has taken over most tasks, oxy-acetylene still earns its place in workshops. It is incredibly versatile. You can heat, bend, cut, braze and repair parts without needing access to mains power. Some restorers and classic car builders still prefer gas welding for thin steel panels because the metal responds gently and the weld can be worked afterwards with a hammer and dolly.

How to Choose the Right Welding Type: Key Comparison Factors

Choosing a welder is easier once you understand how each process behaves in real working conditions. The metal you are joining, the thickness, the environment and even your own experience level all play a part. Below are the main points that influence the choice.

Metal Thickness and Welding Type

Thickness is one of the quickest ways to narrow down your options.

Thin sheet steel behaves very differently from heavy box section, and the wrong method can leave you battling heat, distortion or weak joins.

• Very thin material such as car body panels often suits TIG or a carefully set MIG machine. The heat control helps prevent burn through.
• Medium thickness steel is more forgiving. MIG, TIG, Stick and flux-core can all work, so the choice comes down to preference and finish.
• Thick plate needs power and penetration. Stick and flux-core wire handle this with ease. They dig deep and produce strong, reliable welds without struggling.

If you work across a range of thicknesses, a multi-process inverter might make life easier, but understanding the limits of each method is still essential.

Type of Metal

Different metals call for different skills and settings.

• Mild steel is the easiest. Almost every process works well on it.
• Stainless steel benefits from TIG if appearance matters, though MIG is also common.
• Aluminium demands AC TIG for the cleanest results. MIG can handle it with the right setup, but the finish is rarely as neat.
• Metals like titanium or magnesium sit firmly in TIG territory and require good technique.

Picking the right method for the metal saves frustration and gives you a cleaner, stronger weld.

Skill Requirements

Some processes welcome beginners. Others expect a bit more finesse.

• MIG feels the most approachable. A steady hand and the right settings will get you going quickly.
• Stick and flux-core take a little practice, mainly learning how to strike and hold the arc.
• TIG is the most demanding, as you control heat, filler and movement at the same time. Once mastered, it rewards the effort with precise and beautiful welds.

Understanding your current comfort level helps you choose a method that builds confidence instead of knocking it.

Weld Quality and Aesthetics

If you care about how the finished weld looks, the choice becomes clear.

• TIG produces the neatest, most controlled beads, especially on stainless and aluminium.
• MIG delivers tidy results with far less effort and very little clean up.
• Stick and flux-core produce strong welds but can be messier, leaving slag and spatter that need cleaning.

For functional joints where appearance is secondary, Stick or flux-core shine. For visible, decorative or fine work, TIG takes the lead.

Welding Environment (Indoors vs. Outdoors)

Your surroundings matter more than many people realise.

• Indoors, MIG and TIG work perfectly because the shielding gas stays put.
• Outdoors, Stick and flux-core are the clear winners. Wind has little effect on the shielding, so you can weld with confidence even on rough days.

If you regularly weld outside, avoid fully relying on gas-shielded MIG unless you also plan to use flux-core wire.

Cost Considerations

Budget influences the choice just as much as skill or metal type.

• Stick machines are the cheapest to buy and run. Electrodes are affordable and there is no gas bottle to worry about.
• MIG sits in the middle once you factor in the machine, wire, gas, and regulators.
• TIG tends to cost the most, especially models with AC capabilities. The consumables add up too.

For tradespeople who weld daily, investing in higher quality equipment pays off. For occasional DIY use, choosing a simpler setup may make more sense.

Weld Strength

Strength comes from good penetration, proper heat control and the right filler. Certain methods naturally excel in these areas.

• Stick and flux-core give excellent penetration on thick steel, making them the preferred choice for load-bearing work.
• MIG offers strong, reliable welds on a wide range of materials, provided the settings are correct.
• TIG produces incredibly strong welds when done well, but the technique needs to be consistent to unlock that strength.

Matching the process to the job keeps your welds trustworthy and reduces the chance of rework.

Welding Method	Best Suited For	Skill Level	Common Uses
MIG (GMAW)	General fabrication, automotive, mild steel and stainless projects	Beginner friendly	Car bodywork, brackets, frames, repairs, hobby projects
TIG (GTAW)	Precision work, stainless steel, aluminium and thin material	Advanced	Motorsport parts, stainless fabrications, custom aluminium work, decorative joins
Stick (SMAW)	Heavy steel, outdoor tasks, dirty or rusty material	Moderate	Construction, farm repairs, pipelines, structural steel
Flux-Cored (FCAW)	Thick material, outdoor work, fast production	Moderate	Heavy equipment repairs, structural jobs, shipbuilding, large fabrication

Conclusion: Selecting the Right Welder

Once you understand how each welding method behaves, choosing the right one becomes far less of a guessing game. MIG, TIG, Stick and flux-core each bring their own strengths to the table. Some offer speed, some offer fine control and others simply refuse to give up even in rough conditions.

If you want clean, tidy welds on everyday steel, MIG is a solid all-rounder. When appearance and precision matter, TIG steps forward. Stick earns its place on building sites and farms where the metal is thick, dirty or exposed to the weather. Flux-core comes into its own when you need strong penetration and fast progress on heavier material.

There is no single machine that suits everyone, which is why understanding the main types of welders makes such a difference. The best choice depends on the jobs you handle, your working environment and how experienced you are with a torch in your hand. Once those pieces fall into place, the decision becomes surprisingly straightforward.

Recommended Welding Essentials

Here are some of our most reliable and widely used product ranges. Each category is designed to support both professional workshops and DIY users looking for dependable equipment.

• Welding Helmets – Essential for eye and face protection during any welding task.
• Inverters – Lightweight, versatile machines perfect for ARC and TIG applications.
• MIG Accessories – Wire, tips, and consumables to keep your welder running smoothly.
• Spot & Stud Welders – Designed for bodywork, panel repair, and precision fastening.
• Welding Accessories – Nozzles, clamps, connectors, and the essentials every welder needs.