Why choosing the right welding process saves time, money and rework
Welding is one of the most fundamental manufacturing processes in India’s industrial landscape — used in fabrication, construction, shipbuilding, automotive manufacturing, pressure vessel production, and hundreds of other applications. Yet one of the most common reasons for weld defects, rework, and cost overruns is not skill — it is process selection.
A fabricator using MIG welding on a joint that requires TIG precision will produce a weld that looks acceptable but fails inspection. A contractor using stick welding for a production job that could run five times faster with MIG is losing money every hour. And an engineer specifying the wrong consumable for either process compounds the problem.
This guide gives you a clear framework for choosing between MIG, TIG, and stick welding — and explains which G Weld consumable by GEE Limited is right for each process.
MIG welding (GMAW) — speed, versatility and production efficiency
MIG welding — Metal Inert Gas welding, technically GMAW (Gas Metal Arc Welding) — is the most widely used welding process in Indian fabrication shops and manufacturing plants.
How it works
A continuous wire electrode feeds through the welding gun while shielding gas (typically CO2 or a CO2/Argon mix) protects the weld pool from atmospheric contamination. The wire melts into the joint, forming the weld bead.
Where MIG excels
- High production speed — faster than TIG or stick for most applications
- Suitable for thin to medium thickness materials (1.5mm to 25mm+)
- Works well on mild steel, stainless steel, and aluminium (with appropriate wire and gas)
- Lower operator skill barrier compared to TIG
- Continuous wire feed reduces downtime between passes
Limitations
- Requires shielding gas — not ideal for outdoor work with wind
- Equipment cost is higher than stick welding
- Less suited to very thin materials or precision root passes on pipes
Recommended G Weld consumables for MIG
- G Weld ER70S-6 MIG wire — general purpose mild steel, 0.8mm to 1.6mm diameter
- G Weld ER308L — stainless steel MIG wire for food, pharmaceutical, and chemical equipment
- G Weld ER4043 / ER5356 — aluminium MIG wire for aluminium fabrication and repairs
TIG welding (GTAW) — precision, quality and clean welds
TIG welding — Tungsten Inert Gas welding, technically GTAW (Gas Tungsten Arc Welding) — is the precision process. It is slower than MIG but produces higher quality welds with no spatter and excellent aesthetic finish.
How it works
A non-consumable tungsten electrode creates the arc. The welder feeds a separate filler rod into the weld pool manually. Argon shielding gas protects the weld zone. Both hands are used — one holding the torch, one feeding the rod — requiring significantly higher operator skill than MIG.
Where TIG excels
- Precision root passes on pressure vessels and pipelines
- Thin materials where heat input must be controlled
- Stainless steel, aluminium, titanium, and dissimilar metal joints
- Visible welds requiring aesthetic quality (architectural, food-grade equipment)
- Root passes on pipe joints that will be inspected by X-ray or ultrasound
Limitations
- Slowest of the three processes — not economical for high-volume structural work
- Requires skilled welders — longer training time
- Higher cost per metre of weld versus MIG for most applications
Recommended G Weld consumables for TIG
- G Weld ER70S-2 TIG rod — mild steel, clean finish, low silicon
- G Weld ER308L / ER316L TIG rod — stainless steel pipe and vessel work
- G Weld ER4043 TIG rod — aluminium TIG welding
Stick welding (SMAW) — flexibility, durability, and field performance
Stick welding — technically SMAW (Shielded Metal Arc Welding) — is the oldest and most widely deployed welding process in India. It remains the dominant process for site work, repair welding, and any application where portability matters more than speed.
How it works
A coated electrode (stick) is held in a clamp. When struck against the workpiece, an arc forms. The electrode coating melts to create shielding gas and flux, protecting the weld pool without an external gas supply.
Where stick welding excels
- Outdoor and site welding — wind resistance since there is no separate shielding gas
- Remote locations where gas cylinders cannot be transported
- Repair welding on dirty, rusty, or painted surfaces
- Vertical, overhead, and positional welding
- Heavy structural work — bridges, buildings, heavy plant
Limitations
- Slower than MIG — electrode must be replaced frequently
- More slag and spatter cleanup required
- Less suitable for thin materials or precision applications
Recommended G Weld consumables for stick
- G Weld E6013 — general purpose mild steel, easy arc striking, good for beginners
- G Weld E7018 — low-hydrogen, high-strength joints, structural work, code-quality welds
- G Weld E308L-16 — stainless steel electrodes for site welding of SS equipment
- G Weld EFe-Mn — hard facing electrode for wear-resistant overlay on tools and equipment
Decision guide: choose by material, thickness, and environment
| Mild steel, medium thickness, production shop | MIG — G Weld ER70S-6 |
| Mild steel, structural, outdoor site | Stick — G Weld E6013 or E7018 |
| Stainless steel pipe, root pass | TIG — G Weld ER308L TIG rod |
| Stainless steel sheet, production | MIG — G Weld ER308L wire |
| Aluminium fabrication | MIG or TIG — G Weld ER4043 / ER5356 |
| Repair welding, rusty surface | Stick — G Weld E6013 |
| High-strength structural joint, code required | Stick — G Weld E7018 |
| Thin sheet metal (1.5–3mm) | MIG or TIG depending on quality requirement |
| Pressure vessel root pass | TIG — G Weld ER70S-2 |
Common mistakes in process selection
- Using stick welding for thin sheet — causes burn-through and excessive distortion
- Using MIG on heavily rusted or painted material — leads to porosity
- Using TIG for high-volume structural work — economically inefficient
- Using the wrong wire classification — E.g. ER70S-3 instead of ER70S-6 where higher deoxidizers are needed
Always match the electrode or wire classification to the base metal specification and the mechanical properties required. G Weld product datasheets specify mechanical properties and certifications for each consumable.
Contact Imperiea Engineering for G Weld consumables matched to your welding process and application. Bulk supply with delivery across Maharashtra.
