MIG vs TIG vs Stick Welders: Types and Sizes
MIG is the easiest process to learn, TIG gives the most control on thin metal, and stick handles rusty metal and wind; size by thickness and duty cycle.
By Andrian ChengContributing writer.
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The short answer
Home and shop welders use three main arc processes:
- MIG (GMAW): a wire electrode feeds from a spool through the gun. Miller calls it the easiest process to learn, fast, and clean, with no slag to chip off.
- TIG (GTAW): a tungsten electrode that does not melt, with filler rod added by hand. It gives the most control and the neatest beads, but it is slower and harder to master.
- Stick (SMAW): a coated rod is the electrode. It copes with wind, rust and dirt, and costs the least, but it spatters and the weld needs cleaning.
Flux-cored welding runs on the same machines as MIG but uses a wire whose core shields the arc, so it needs no gas bottle and works outdoors.
MIG vs TIG vs stick at a glance
These points come from Miller's guide for first-time buyers:
| Process | Learning curve | Thinnest metal | Works outdoors | Typical uses |
|---|---|---|---|---|
| MIG | Easiest | 26 gauge | Needs gas shielding; flux-core wire does not | Auto body, trailers, general fabrication |
| TIG | Hardest | Thin sections, its strong point | Needs gas shielding | Stainless, aluminum, copper, show welds |
| Stick | Hard to strike and hold an arc | 18 gauge | Good | Farm repair, field work, thick or dirty steel |
For aluminum, TIG uses AC current, which cleans the oxide layer on the surface; steel and stainless are TIG welded on DC.
A multi-process welder puts MIG, flux-cored, stick and often DC TIG in one box. On Wiki Shopping, 25 welders list multi-process capability.
What size welder do I need
Size comes down to amperage, and amperage follows metal thickness. Miller's rule of thumb is about 1 amp for every 0.001 inch of thickness:
| Metal thickness | Amps needed (approx.) | Example projects from Miller's guide |
|---|---|---|
| 1/16 in | about 63 A | Bicycles, lawn mowers, tube frames |
| 1/8 in (0.125 in) | about 125 A | Boats, motorcycles, utility trailers |
| 1/4 in (0.250 in) | about 250 A | Trailer frames, heavy repair |
Input power sets a ceiling. Miller lists its 120-volt Millermatic 142 for 24 gauge up to 3/16 inch mild steel in one pass, while its Multimatic 215, which runs on 120 or 240 volts, welds up to 3/8 inch. Dual-voltage machines like that take either plug; 30 welders on Wiki Shopping list dual voltage and 7 list 120V input.
What duty cycle means
Duty cycle is the share of a 10-minute period a welder can run at a given amperage before it must cool down. Divide the percentage by 10 to get minutes:
- 30% at 215 A (Miller's Millermatic 211 PRO): 3 minutes of welding, then 7 minutes of rest.
- 60% at 105 A, 20% at 200 A (Miller's Multimatic 220 AC/DC, MIG): the same machine runs longer at lower amps.
Always compare duty cycles at the same amperage. Miller notes that garage users, who stop often and weld at lower amps, are usually fine with a lower rating, while production welders tend to want 60%.
How we count
Welding process and input voltage come from each welder's store listing. Welders that do not state a process are left out of the chart. The counts change as listings are added or removed.
Shop by spec
Welders
Spec score 7.9
Multi-process, 160 Max output, Dual voltage
+Dual 110V and 220V input for flexible power use
+Four processes: MIG, flux core, Lift TIG and stick
+Synergic control and clear digital display
$149.99-34%List: $225.99
as of 11/04/2026 08:41 PST - DetailsProduct details
$149.99as of 11/04/2026 08:41 PST - Details
View on AmazonSpec score7.9
Pros
+Dual 110V and 220V input for flexible power use
+Four processes: MIG, flux core, Lift TIG and stick
+Synergic control and clear digital display
Compared with this page−160 max output: 15 of the 24 here have a higher max output
How pros and cons are picked (About: Disclaimer)About this product
- MULTIFUNCTIONAL: A 4-in-1 welder, capable of Flux Core MIG/Gas MIG/ Stick/Lift TIG (need to purchase extra tig lift torch). This unit caters to a wide range of welding applications and meets your various welding needs.
- WELDING CAPACITY: With a robust 160A output, 110V/220V dual voltage, this welder is in possess of reliable quality and stable performance. It's widely used in various scenarios, including automotive, construction, fabrication and DIY. This Welder can work with 2LB and 10LB spools of .030"(0.8mm) and .035" (0.9mm) solid core wire, flux core wire. It also performs well with most 6010, 6011, 6013 and 7018 rods in Stick Welding mode.
- SMART CONTROL: Smart control refers to Synergic control, when selecting different thicknesses or adjust the amperage, the recommend voltage and wire feeding speed will be automatically switched into. Great choice for beginners.
- MANUAL CONTROL: You can manually adjust the wire feeding speed and voltage according to your preferences, which is ideal for seasoned professionals and DIYers.
- LED DISPLAY: Advanced LED digital display, subverts the traditional visual experience, increases the visual clarity and improves the efficiency of the operation.
- PORTABLE&POWERFUL: Only weighs 19.4lb(8.8kg), this lightweight and compact welder is a breeze to transport, and it can be plugged into 110V/220V dual voltage, making it the perfect companion for on-the-go welding projects with its carrying handle.
- SAFETY PRIORITIZED: Our product features comprehensive safeguards, including automatic compensation for voltage fluctuation, robust protections against over-current, over-load, and over-heating, ensuring unparalleled user safety and device longevity.
TIG, Dual voltage
+Dual voltage input for 120V and 240V use
+Five processes covered in one unit
+DC TIG and cold TIG modes available
$249.99-29%List: $349.99
as of 11/03/2026 21:53 PST - DetailsProduct details
$249.99as of 11/03/2026 21:53 PST - Details
View on AmazonPros
+Dual voltage input for 120V and 240V use
+Five processes covered in one unit
+DC TIG and cold TIG modes available
How pros and cons are picked (About: Disclaimer)About this product
- FIRST APP-CONTROLLED TIG WELDER: The ARCCAPTAIN TIG205 Pro welder, allows users to connect to a mobile APP by scanning a QR code on the welder. It supports multiple devices, real-time monitoring of welder status, multifunctional welding process selection, parameter adjustments, error code analysis, FAQs, and sharing of welding results for educational purposes. Join the ARCCAPTAIN welding community and ignite endless welding fun!
- 5-IN-1 MULTI-PROCESS TIG WELDER: The ARCCAPTAIN TIG205 Pro is a 205 amp welding machine that features COLD TIG, 4T DC TIG, COLD SPOT TIG, 2T DC TIG, and STICK. It operates on DC output only and does not support AC, so it is not suitable for aluminum welding. It is also compatible with the ARCCAPTAIN 5-pin TIG foot pedal and WP-17 TIG torch, allowing for remote control of the entire TIG welding process without needing to free up a hand to adjust the current switch. This saves time and boosts efficiency and productivity. Additionally, it can be integrated with a cold welding helmet. (Note: Foot pedal/cold welding helmet not included.)
- LARGE LED DISPLAY: The smart LED screen design provides accurate data display and more options, making it easier and clearer to read without removing your helmet. It performs well on steel, stainless steel, and chrome-moly steel, making it ideal for outdoor maintenance, garages, farms, crafts, and home DIY projects.
- MCU PRECISION CONTROL: Featuring exclusive internal MCU control, the DC TIG welding provides a 99.99% arc initiation success rate with a 400% increase in arc start response speed, meeting the low-temperature precision control needed for sheet metal or bodywork. The precise control algorithms enhance electrode welding performance: smooth arc initiation, stable current, minimal spatter, no electrode sticking, excellent shaping, and automatic adaptation to cable length and cross-sectional changes.
- SAFE AND DURABLE: The ARCCAPTAIN TIG205 Pro has passed various professional tests and certifications, including ANSI/FCC standards, and comes with a 3-year warranty and lifetime technical support. In addition to features like VRD (Voltage Reduction Device), overheat, overcurrent, and undervoltage protection, the TIG205 Pro incorporates a unique custom airflow design to prevent metal dust and solid particles from entering the core control unit, ensuring stable operation and longevity.
Spec score 8.8
Multi-process, 200 Max output, Dual voltage
+200A output for thicker metal work
+AC and DC TIG welding available
+Pulse function included on the machine
−Square and triangular waveform options listed for advanced settings
$649.99-28%List: $899.99
as of 11/03/2026 21:53 PST - DetailsProduct details
$649.99as of 11/03/2026 21:53 PST - Details
View on AmazonSpec score8.8
Pros
+200A output for thicker metal work
+AC and DC TIG welding available
+Pulse function included on the machine
+Handles aluminum welding
+Dual voltage input for 110V and 220V use
Cons−Square and triangular waveform options listed for advanced settings
Compared with this page+Aluminum welding: only 10 of 81 here have one
+Pulse mode: only 15 of 81 here have one
How pros and cons are picked (About: Disclaimer)About this product
- POWERFUL 7-IN-1 TIG WELDER AC/DC: The Welder is capable of welding with DC TIG / DC Pulse TIG / AC TIG / AC Pulse TIG / AC Pulse TIG Square / AC Pulse TIG Triangular / STICK /SPOT TIG Methods. AC TIG is used in finesse welding various aluminum alloys, magnesium alloys, and other non-ferrous metals. DC TIG provides low-temperature control. You need precise welding for various types of steel: stainless steel, carbon steel, copper.
- LARGE LED DISPLAY AlUMINUM TIG WELDER : ARCCAPTAIN Tig welder can weld 0.5MM-5MM (0.02"–0.20") aluminum and 0.5MM-10MM (0.02"–0.39") metals. Enjoy enhanced visibility with the TIG200PACDC large LED screen, providing clear display of welding parameters, settings, this screen ensures effortless operation, providing precise control over your welds in any environment.
- PULSE & SQUARE & TRIANGULAR WAVEFORM: The ac/dc TIG welder is equipped to prevent the burning of materials and minimize material distortion from excessive heat input, as well as the triangular wave reduces the heat input effectively, so the weld forms rapidly. It is easy for thin metal welding; Square Wave can switch the polarity quickly, dynamic arc for a stable weld pool, a strong ability to clean aluminum oxide film, so it provides more precise welding on aluminum or aluminum alloy.
- DIGITAL WEDLING PARAMETER SET: MCU Digital control system makes this machine more reliable and stable. Parameters such as Pre-flow, Initial current,Up-slope, Peak current, Base current, Down-slope,Crater current, Post-flow, Pulse duty, AC frequency, AC balance, Pulse frequency,are easily adjustable,and 2T/4T/Spot welding TIG torch control and foot pedal remote control (not included) methods which improve good welding performance.
- 3 YEARS QUALITY SERVICE : We have professional personnel who can provide you with answer. The user-friendly and simple interface enables the operators to set it up easily and efficiently, data and dynamic output current will be displayed immediately. Spike withstanding IGBT saves space and weight. It's only 12 kg (26.5lb) . No heavy carrying! Note: DON'T power on until the screen turns off and the fan stops working!
Spec score 7.6
Multi-process, 135 Max output, 120V
+Runs on standard 120V household power
+Multi-process: MIG, flux core, Lift TIG and stick
+135A output for light to medium welding jobs
−Lower 135A output limits thicker material welding
$109.99-27%List: $149.99
as of 11/04/2026 08:41 PST - DetailsProduct details
$109.99as of 11/04/2026 08:41 PST - Details
View on AmazonSpec score7.6
Pros
+Runs on standard 120V household power
+Multi-process: MIG, flux core, Lift TIG and stick
+135A output for light to medium welding jobs
+Clear digital display for setting parameters
Cons−Lower 135A output limits thicker material welding
Compared with this page−135 max output: 20 of the 24 here have a higher max output
How pros and cons are picked (About: Disclaimer)About this product
- READY OUT OF THE BOX: Start welding immediately! It masterfully handles Gasless Flux Core MIG, Stick, and Lift TIG (Extra Lift TIG torch required). This budget-friendly 3-in-1 machine includes extra E71T-GS .030''&.035'' flux core wires, known for its smooth arc and high feedability. Say goodbye to heavy shielding gas cylinders-perfect for outdoor, windy, or all-position welding.
- SAY GOODBYE TO BURN-THROUGHS: Unlike rigid auto-welders, our upgraded Synergic Control automatically matches the recommended voltage to your wire feed speed, making it foolproof for beginners. Plus, the ±3V voltage micro-adjustment allows seasoned professionals to fine-tune the arc. This precise control is the ultimate solution for tackling thin auto body panels without burning through.
- CRYSTAL-CLEAR LED DISPLAY: Never squint at your welder's settings again. Our advanced, oversized digital display revolutionizes the visual interface, offering enhanced clarity even in bright outdoor environments. Monitor real-time current during operation for precise control over every weld.
- ROBUST POWER YET ULTRA-PORTABLE: Weighing only 11.4 lbs with a convenient carrying handle, it's the perfect on-the-go companion. Delivering a robust 135A output (110V), it effortlessly tackles mild steel up to 3/32" (2.5mm) thick. Engineered with an upgraded drive system for smooth wire feeding to prevent annoying jams.
- SAFETY PRIORITIZED & STABLE ARC: The machine features comprehensive built-in safeguards, including robust protections against over-current, over-load, and over-heating, guaranteeing unparalleled user safety, device longevity, and fewer circuit interruptions.