Customers often ask which welding process we will use on their parts. The honest answer is: it depends on the material, the thickness, the appearance you need and the quantity. At Orsolini Welding & Fabricating our certified welders use all three main arc welding processes, so we can match the method to the job instead of the other way around.
MIG welding (GMAW)
MIG welding feeds a continuous wire electrode through a gun while a shielding gas protects the weld pool.
- Best for: carbon steel and many aluminum parts, medium to thick material, and production runs.
- Strengths: fast, efficient and consistent, which keeps costs down on larger quantities.
- Things to know: it needs a clean surface and a sheltered environment, because wind can blow away the shielding gas.
MIG is the workhorse for brackets, frames, guards and most general fabrication in a shop setting.
TIG welding (GTAW)
TIG welding uses a non-consumable tungsten electrode, with filler rod added by hand. It gives the welder very fine control over heat and the weld bead.
- Best for: stainless steel, aluminum, thin sheet metal and parts where appearance matters.
- Strengths: clean, precise, attractive welds with minimal spatter.
- Things to know: it is slower and requires a highly skilled welder, so it usually costs more per inch of weld.
We choose TIG for visible stainless parts, thin enclosures and any job where a clean finish is part of the specification.
Stick welding (SMAW)
Stick welding uses a flux-coated electrode. The coating creates its own protective gas and slag, so no separate gas bottle is needed.
- Best for: thick carbon steel, heavy-duty repairs and less-than-perfect surface conditions.
- Strengths: strong, deep-penetrating welds; very forgiving of rust, paint or mill scale.
- Things to know: slag must be chipped off and the finish is rougher than MIG or TIG.
Stick welding is ideal for heavy industrial components and repair work where strength is more important than looks.
Quick comparison
- Speed: MIG is fastest, stick is moderate, TIG is slowest.
- Appearance: TIG is cleanest, MIG is good, stick is functional.
- Thin material: TIG is best, MIG is good, stick is not ideal.
- Thick material: stick and MIG excel.
- Stainless and aluminum: TIG first, MIG for production work.
How we choose the right process
Before welding begins, we look at the drawing, the material grade and thickness, the joint design, the quantity and any finish or inspection requirements. Many assemblies use more than one process. For example, a stainless enclosure may be TIG welded on visible seams and MIG welded on internal supports.
The goal is always the same: a strong, code-compliant weld at a fair price. If you are not sure what your part needs, just tell us how it will be used and we will recommend the best approach.
Explore our welding and fabrication services or send us your drawings for a quote.