Defence Metal Fabrication: MIG vs TIG Welding for Defence Applications: When Should You Use Each?

MIG and TIG are two commonly used arc-welding processes in metal fabrication. The correct choice in Defence metal fabrication applications depends on factors including the material, component thickness, joint design, production volume, finish requirements and applicable inspection criteria. 

At Universal Wolf we offer MIG and TIG welding as part of our full-service Defence metal fabrication capability. We are certified to DIN 2303 Q2/BK1 and ISO 3834-2, supporting controlled welding for demanding Defence applications.

Our customer specifications and approved welding procedures are paramount in the careful selection of the welding application we use on each product. 

What’s the difference between MIG and TIG welding?  

OSHA describes MIG/GMAW as using a consumable filler-metal electrode with external gas shielding, while TIG/GTAW uses a non-consumable electrode and is noted for its superior finish.

For every Defence component, either MIG or TIG welding will be the better choice to meet mission requirements. The right welding process will turn designs into products that work and last. 

Welding decisions in Defence manufacturing can have an impact on the overall look of the welded joint, production capacity, inspection requirements and long-term performance of the component. 

Attributes that better suit MIG versus TIG

GMAW is more commonly known as metal arc welding or MIG 

GTAW is more commonly known as gas tungsten arc welding or TIG 

MIG is generally selected when productivity and repeatability are priorities.

TIG is favoured when the application demands robust control and a high-quality finish. 

On occasion, exclusive use MIG or TIG may not be the answer. Some assemblies are more suited to a combined approach where the applicable specification and approved Welding Procedure Specification permit the use of both processes. 

When is MIG welding used?

MIG welding uses a continuously fed wire electrode to produce strong, efficient welds, making it well suited to larger components and repeat-production work. 

In defence metal fabrication, MIG welding can be suited to equipment frames, mounting systems, protective enclosures and repeat-production steel assemblies where strength, consistency and production efficiency are key. 

For example, MIG welding may be used on a repeat-production steel frame or mounting bracket where consistent weld quality, good deposition rates and efficient throughput are important. With this in mind we primarily used TIG welding for our customer BAE systems on their Tactica programme.

With MIG welding there are considerations that need to be well managed such as spatter, post-weld finishing, shielding-gas disruption and the need to control distortion. 

When is TIG welding used?  

TIG welding is a precise welding process that uses a non-consumable tungsten electrode to create a controlled, high-quality weld. 

In defence metal fabrication, TIG welding can be a strong choice for intricate, thin gauge components, tight tolerances and applications where the finish and weld quality are critical 

For example, TIG welding may be used on a thin stainless-steel enclosure where the weld needs to be clean, controlled and suitable for close inspection without excessive post-weld finishing.

TIG uses the tungsten electrode to create the arc, but the electrode itself does not melt into the weld; instead, any filler material is added separately by hand when needed. This separation allows the welder to control the heat and filler input independently, giving much finer control over the weld pool, bead profile and overall finish. 

TIG is generally the slower of the two procedures and is more dependent on both operator skill and execution and careful surface preparation. 

From vehicle structures to precision assemblies: where each fits 

When working with Defence applications we must consider additional variables such as weight, corrosion resistance and environmental performance when choosing suitable processes.

MIG-aligned applications could include larger steel structures, equipment frames, mounting systems, protective enclosures and repeat-production weldments. 

TIG-aligned applications could include thin-wall enclosures or housings, specialist stainless or aluminium assemblies and tightly controlled repair work. 

Questions to ask yourself when looking a the type of welding needing for the product:

1. What material and alloy are being joined? MIG is often suitable for carbon steel and thicker aluminium, while TIG is typically preferred for stainless steel, thin aluminium and specialist alloys.
2. How thick is the component? MIG is usually better for medium-to-thicker sections, while TIG is more appropriate for thin-gauge materials.
3. How complex or accessible is the joint? TIG is often better for intricate or hard-to-access joints, while MIG suits simpler joints with good access and longer runs.
4. Is the priority production throughput or fine process control? Use MIG where speed and repeatability matter most; use TIG where precise heat input and control are critical.
5. What inspection and acceptance criteria must the weld meet? The selected process must meet the approved procedure, inspection requirements and acceptance criteria.

Which welding process is right for your Defence component? 

There is no universal answer to whether MIG or TIG is “best”. 

In defence metal fabrication manufacturing, the correct answer is always the process that satisfies the specification. 

Need support to determine the most appropriate welding and fabrication route for a defence component?  

Speak to our team about your requirements today. 

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