With the development of industrial automation and precision manufacturing, the traditional welding methods are far from being able to meet all the application requirements, TIG, MIG, Laser Welding, PAW (Plasma Arc Welding) and other welding processes came into being, and in their respective fields to show unique advantages.

Differences in Process Principles

- Tungsten Inert Gas Welding (TIG): the arc is generated between the tungsten electrode and the workpiece, without melting the electrode, the shielding gas shielding air; high precision, manual operation.

- Metal Inert Gas Welding (MIG): the arc is between the wire and the workpiece, the wire is automatically fed, melted and filled. Welding speed, suitable for batch welding.

- Laser welding (Laser): A high-energy laser beam is used to melt the metal, allowing precise control of depth and shape. Non-contact, low heat impact.

- Plasma Arc Welding (PAW): A plasma arc is formed by shrinking the nozzle, the arc column is more concentrated, the heat density is high, and it can weld thick plates with deep melting.

Welding thickness range

- TIG: Suitable for ultra-thin to medium thickness materials, 0.1~6mm, ideal for thin wall welding of stainless steel and titanium alloys.

- MIG: Suitable for medium-thickness plates, especially carbon steel, structural steel and aluminum alloy, with high efficiency and wide coverage.

- Laser: Suitable for ultra-thin materials up to 6mm or less, such as lithium battery seals and motor end caps. Thick plates require multi-channel scanning.

- PAW: Wide range, 0.1mm thin plate to 10mm thick plate can be handled, but also can realize keyhole mode welding.

Weld seam aesthetics

TIG: the most beautiful weld seam, the surface is flat, the grain is like fish scale, commonly used in meet or high-end crafts.

MIG: wider weld seam, more spatter, suitable for structural parts that do not require the appearance of the weld seam.

Laser welding: extremely narrow and delicate weld seam, almost no need for post-processing, second only to TIG in terms of value, but the speed is far ahead.

PAW: better than MIG, second to TIG, but more suitable for deep fusion welding and automation.

Adaptability to automation

laser welding and PAW are kings when it comes to automation integration:

-   High accuracy

-   Tracks weld seam trajectory

-   Can be combined with robotics/vision systems

MIG is also widely used in automated production lines, e.g. in automotive manufacturing.

Although TIG can realize automatic orbital welding, it is still highly dependent on the welder’s skill.

Comparison of TIG, MIG, LASER and PAW

TIG, MIG, Laser and Plasma Arc Welding (PAW) each represent welding solutions for different application scenarios:

TIG welding: known for the quality and aesthetics of the weld seam, suitable for thin plate materials requiring high welding precision, especially commonly used in high-end manufacturing of stainless steel and titanium alloys;

MIG welding: high efficiency, easy to operate, suitable for medium-thick plate and mass production, is the main process in automotive, construction, machinery and other fields;

Laser welding: fast speed, low heat impact, high degree of automation, widely used in 3C electronics, power batteries, precision instruments and other high-end manufacturing;

PAW welding: combining the stability of TIG and the deep melting ability of laser, it is suitable for aerospace, pressure vessels and other critical parts with high strength and high sealing requirements.

The choice of which process should be based on the type of material, welding thickness, quality requirements, cost control and automation level to make a comprehensive judgment.