MIG vs TIG vs Stick Welding

When you’re standing in a Toronto fabrication shop or planning a repair for your Mississauga manufacturing facility, the question isn’t just “Can this be welded?” It’s “Which welding method will give me the strongest, most cost-effective result?”

After 21+ years serving Ontario’s industrial, commercial, and residential sectors, we’ve seen firsthand how choosing the wrong welding process can turn a $500 repair into a $2,000 disaster. But here’s the reality: MIG, TIG, and Stick welding each excel in specific situations—and understanding when to use which method can save you thousands while ensuring your project stands the test of Ontario’s harsh winters and demanding industrial environments.

This guide breaks down the real costs, practical applications, and critical decision factors for each welding method, all through the lens of actual Ontario projects we’ve completed across the GTA.

MIG vs TIG vs Stick Welding – Understanding the Three Major Welding Processes

Before diving into cost comparisons, let’s establish what makes each method unique and when Ontario contractors, manufacturers, and property owners typically need them.

MIG Welding (GMAW – Gas Metal Arc Welding)

MIG welding feeds a continuous wire electrode through a welding gun while shielding gas (usually a mix of argon and CO2) protects the weld pool from contamination. Think of it as the “high-speed production” method.

How it works: The welder pulls the trigger, and wire automatically feeds through while gas flows around the arc. This makes it faster than other methods and easier for beginners to learn.

Typical Ontario applications:

• Automotive body repairs at Toronto collision centers
• Structural steel fabrication for Brampton warehouses
• Manufacturing production lines in Hamilton
• Agricultural equipment repairs across rural Ontario
• Residential fence and gate installations in the GTA

At RS Mobile Welding, our MIG welding services handle everything from quick automotive fixes to large-scale commercial fabrication, making it our most requested service for time-sensitive projects.

TIG Welding (GTAW – Gas Tungsten Arc Welding)

TIG welding uses a non-consumable tungsten electrode to create the arc while the welder manually feeds filler rod into the weld pool. It’s the “precision surgery” of welding.

How it works: The welder controls the tungsten torch with one hand while feeding filler rod with the other, allowing precise control over heat and material deposition. This requires significant skill but produces the cleanest, strongest welds.

Typical Ontario applications:

• Stainless steel fabrication for Toronto restaurant kitchens
• Aluminum welding for boat repairs in cottage country
• Aerospace components at Ontario manufacturing facilities
• High-end architectural metalwork in downtown Toronto
• Medical equipment fabrication requiring sanitary welds

Our TIG welding expertise is what Ontario businesses call on when appearance, strength, and precision are non-negotiable—particularly for stainless steel and aluminum projects.

Stick Welding (SMAW – Shielded Metal Arc Welding)

Stick welding uses a consumable electrode rod coated in flux. When the arc is struck, the flux coating creates its own shielding gas and slag, which protects the weld.

How it works: The welder strikes an arc between the electrode stick and the base metal. As the electrode melts, its flux coating creates protective gas and slag that must be chipped away after welding.

Typical Ontario applications:

• Heavy structural steel for construction sites across Ontario
• Pipeline welding in Northern Ontario
• Outdoor repairs in windy or inclement conditions
• Thick steel fabrication for industrial equipment
• Emergency repairs where portability is critical

Our Stick welding services remain essential for outdoor Ontario projects and industrial applications where thick steel and challenging conditions are the norm.

The Real Cost Breakdown: What Ontario Businesses Actually Pay

Understanding welding costs isn’t just about the hourly rate—it’s about total project cost including setup, material, time, and long-term durability. Here’s what we’ve learned from thousands of projects across the GTA.

Equipment Investment Costs

For Ontario Contractors and Fabrication Shops:

Key insight for Ontario businesses: MIG offers the fastest return on investment for production work, while Stick provides the lowest entry cost for construction contractors doing structural work.

Labor Efficiency and Speed Comparison

Based on actual Ontario job data from RS Mobile Welding projects:

Welding 100 feet of 1/4″ mild steel:

• MIG welding: 2-3 hours = $300-$450 in labor
• TIG welding: 5-7 hours = $750-$1,050 in labor
• Stick welding: 4-5 hours = $600-$750 in labor

Why MIG wins for production: For our industrial welding clients in Mississauga and Hamilton, MIG’s continuous wire feed means 50-75% faster completion times compared to TIG or Stick for the same project scope.

Material Costs and Waste

Real Ontario project example: A Vaughan manufacturer needed 200 linear feet of steel frame welding for custom storage racks.

• MIG: $120 in wire + gas, 5% material waste = $126 total
• TIG: $180 in filler + gas, 3% waste = $185 total
• Stick: $80 in electrodes, 8% waste (stub ends) = $86 total

The winner varies by project: While Stick has lower consumable costs, the stub ends (last 2″ of each electrode) create waste. MIG’s continuous feed eliminates this, making it more cost-effective on larger projects despite higher per-unit material costs.

Total Project Cost Analysis

Let’s examine three common Ontario scenarios:

Scenario 1: Automotive exhaust repair (mild steel, 3-4 welds)

• MIG: $150-$200 total ✅ BEST VALUE
• TIG: $250-$350 total (overkill for the application)
• Stick: Not recommended (too crude for thin automotive materials)

Scenario 2: Stainless steel restaurant equipment repair

• MIG: $350-$500 (acceptable but may show discoloration)
• TIG: $400-$600 ✅ BEST VALUE (clean, sanitary, meets health code)
• Stick: Not suitable for stainless steel this thin

Scenario 3: Structural steel beam repair for warehouse

• MIG: $800-$1,200 (faster but requires clean surface)
• TIG: $1,500-$2,200 (unnecessary precision for structural work)
• Stick: $700-$1,000 ✅ BEST VALUE (penetration, works on rusty steel)

These real scenarios from our custom metal fabrication portfolio show why method selection matters more than hourly rates.

Material Compatibility: Matching the Right Process to Your Ontario Project

Ontario’s diverse industries work with everything from aluminum boat repairs in Muskoka to stainless steel food processing equipment in Cambridge. Here’s which methods work best for each material.

Steel and Mild Steel

Ontario use cases: Construction beams, automotive frames, manufacturing equipment, gates, fences, structural supports

MIG welding on steel:

• ✅ Fastest option for production work
• ✅ Excellent for clean, thin to medium thickness (up to 3/8″)
• ✅ Best for automotive welding projects
• ❌ Struggles with rusty or painted surfaces common on older Ontario structures

TIG welding on steel:

• ✅ Superior weld quality and appearance
• ✅ Ideal for thin materials (1/16″ to 1/4″)
• ✅ Best when visual appearance matters (architectural work)
• ❌ Significantly slower, increasing labor costs

Stick welding on steel:

• ✅ Works on rusty, painted, or dirty surfaces (common in Ontario winters)
• ✅ Excellent penetration on thick steel (1/4″ and up)
• ✅ Best for outdoor construction and structural work
• ❌ Rougher appearance, requires more grinding/finishing

Ontario recommendation: For new fabrication in controlled environments, choose MIG. For outdoor structural repairs or thick steel, Stick excels. Reserve TIG for when appearance is critical.

Stainless Steel

Ontario use cases: Restaurant equipment, food processing machinery, pharmaceutical facilities, architectural features, marine applications

MIG welding on stainless:

• ✅ Possible with proper wire and shielding gas (tri-mix)
• ⚠️ May cause slight discoloration or sugaring on back side
• ⚠️ Requires very clean surface preparation
• Best for: Non-critical structural stainless work

TIG welding on stainless:

• ✅ Superior corrosion resistance ✅ INDUSTRY STANDARD
• ✅ Clean, polished appearance meeting health codes
• ✅ No discoloration or contamination
• ✅ Required for sanitary applications
• Best for: All stainless steel fabrication in food service, medical, and architectural applications

Stick welding on stainless:

• ✅ Possible with special stainless electrodes
• ❌ Difficult to control heat, often causes warping
• ❌ Poor appearance, extensive grinding required
• Generally not recommended for Ontario commercial applications

Ontario recommendation: TIG is the clear choice for stainless steel. While MIG can work for some structural applications, TIG’s clean, corrosion-resistant welds justify the higher cost for commercial and food-service projects.

Aluminum

Ontario use cases: Boat repairs, automotive components, aerospace parts, architectural panels, recreational vehicle work

MIG welding on aluminum:

• ✅ Faster than TIG (when properly set up)
• ⚠️ Requires spool gun or push-pull system (aluminum wire is soft)
• ⚠️ More spatter and cleanup than TIG
• Best for: Production aluminum work, thicker materials (3/16″+)

TIG welding on aluminum:

• ✅ Superior control and weld quality ✅ INDUSTRY STANDARD
• ✅ Essential for thin aluminum (under 1/8″)
• ✅ Clean, precise welds with minimal cleanup
• ✅ Best for aluminum welding repairs and critical applications
• Best for: All precision aluminum work, thin materials, aerospace components

Stick welding on aluminum:

• ❌ Extremely difficult and rarely used
• ❌ Requires specialized electrodes and techniques
• Not recommended for Ontario commercial applications

Ontario recommendation: TIG is the overwhelming choice for aluminum work. MIG can be cost-effective for production environments with thicker aluminum, but TIG remains the standard for repairs and precision work.

Cast Iron

Ontario use cases: Machinery repairs, vintage automotive restoration, industrial equipment, heritage building repairs

MIG welding on cast iron:

• ⚠️ Possible with nickel-based wire
• ⚠️ Requires extensive preheat (expensive in Ontario energy costs)
• Best for: Small repairs with proper preparation

TIG welding on cast iron:

• ✅ Excellent control for precision repairs
• ✅ Reduced heat input compared to other methods
• Best for: Detailed restoration and thin cast iron

Stick welding on cast iron:

• ✅ Traditional method with proven track record ✅ MOST COMMON
• ✅ Works with nickel or nickel-iron electrodes
• ✅ More forgiving of contamination and impurities
• Best for: Large machinery repairs, structural cast iron work

Ontario recommendation: Stick welding remains the workhorse for cast iron repairs across Ontario’s manufacturing sector, though TIG offers advantages for detailed restoration work.

Certification and Standards in Ontario

Ontario follows Canadian Welding Bureau (CWB) standards for professional certification. Here’s how requirements differ:

CWB Certification levels:

• All-position certification: Can weld in any position (flat, horizontal, vertical, overhead)
• Process-specific: Certified for MIG, TIG, Stick, or combination
• Material-specific: Steel, stainless steel, aluminum require separate certifications

Typical Ontario requirements:

For construction and structural work:

• CWB Division 1 (Fusion Welding of Steel) certification required
• Stick welding most common
• MIG increasingly used for production structural work

For pressure vessels and piping:

• CWB Division 2 certification mandatory
• TIG often required for critical welds
• Higher certification costs and inspection requirements

For general fabrication and manufacturing:

• CWB certification recommended but not always mandatory
• Client specifications typically dictate requirements
• Mix of MIG, TIG, and Stick based on application

RS Mobile Welding’s certifications: Our team holds CWB W47.1 certification for structural steel welding, ensuring our work meets Ontario Building Code requirements and insurance standards.

Ontario Labor Market Reality

Current skilled trades landscape across the GTA:

High demand, limited supply:

• Experienced TIG welders: Most scarce, highest wages
• Structural stick welders: Strong demand, moderate availability
• Production MIG welders: Most available, competitive wages

Geographic variations:

• Downtown Toronto/GTA core: Higher wages, more competition for skilled welders
• Hamilton/industrial belt: Strong welder availability, industrial focus
• Rural Ontario: Limited welder availability, often requires mobile services
• Northern Ontario: Premium wages for remote industrial projects

Business decision factor: If your Ontario project timeline is tight, MIG’s larger labor pool can mean faster project completion compared to searching for specialized TIG welders.

Application-Specific Recommendations for Ontario Industries

Let’s break down actual Ontario use cases to show which welding method delivers the best value for different sectors.

Automotive and Transportation

Body repair shops (Toronto, Mississauga, GTA):

Scenario: Repairing rust damage on vehicle frame rails, quarter panels, and floor pans.

Recommended method: MIG welding ✅

• Why: Thin sheet metal requires low heat input
• Cost advantage: Fast completion = lower labor costs
• Quality: Clean welds easily ground smooth for body filler
• Alternative: TIG for show cars requiring invisible welds

Our automotive welding services handle everything from frame straightening to custom exhaust work, with MIG as our primary process for production efficiency.

Heavy truck and trailer repair:

Scenario: Frame crack repairs, hitch welding, aluminum trailer body repairs.

Recommended method: MIG for steel, TIG for aluminum ✅

• Why: MIG handles thick steel frames efficiently
• Ontario advantage: Mobile service minimizes transportation downtime
• TIG requirement: Aluminum trailers need precision welding
• Stick alternative: Acceptable for heavy frame repairs in field conditions

Real cost comparison:

• Steel trailer hitch repair (MIG): $250-$400
• Same repair (Stick): $350-$500 (slower, more cleanup)
• Aluminum body repair (TIG): $450-$700 (no substitute available)

Manufacturing and Industrial

Production fabrication (Hamilton, Cambridge, Kitchener manufacturing corridor):

Scenario: High-volume welding of steel assemblies, brackets, frames, and components.

Recommended method: MIG welding ✅✅✅

• Why: Speed is paramount—MIG is 2-3x faster than alternatives
• Cost impact: Labor savings often exceed $50-$100 per day per welder
• Quality: Consistent, repeatable welds with minimal training
• Automation potential: MIG robots for highest-volume runs

Ontario manufacturing reality: Our industrial welding clients in the Golden Horseshoe save 40-60% in labor costs using MIG versus Stick for production work.

Heavy equipment and machinery repair:

Scenario: Bucket teeth, hydraulic mounts, structural components, and wear parts.

Recommended method: Stick welding ✅

• Why: Thick steel, often contaminated with dirt/oil
• Field advantage: Stick works in dusty shop environments
• Durability: Deep penetration ensures strong repairs on wear items
• Cost: Lower equipment investment for repair shops

Food processing and pharmaceutical (GTA, Guelph area):

Scenario: Stainless steel tanks, piping, processing equipment requiring sanitary welds.

Recommended method: TIG welding ✅✅

• Why: Sanitary requirements demand TIG’s clean, smooth welds
• Regulation compliance: Food safety inspectors require porosity-free welds
• Corrosion resistance: TIG prevents contamination that causes rust
• No alternative: Health codes essentially mandate TIG for food contact surfaces

Our stainless steel fabrication work in Toronto-area restaurants and food facilities exclusively uses TIG to meet health department standards.

Construction and Structural

Commercial building construction (GTA development sites):

Scenario: Structural steel beams, columns, bracing, and connections.

Recommended method: Stick welding ✅

• Why: All-position capability (overhead, vertical, horizontal)
• Ontario Building Code: Structural welds require CWB certification (all methods accepted)
• Weather resistance: Wind and outdoor conditions favor Stick
• Cost advantage: Faster than TIG, works on less-than-perfect steel

Alternative for modern construction: MIG increasingly used for structural work when conditions allow (indoor welding of fabricated assemblies).

Infrastructure and Civil Projects:

Scenario: Bridge repairs, pipe welding, railing installation, roadway barriers.

Recommended method: Stick welding ✅✅

• Why: Thick materials (often 1/2″ to 1″ steel plate)
• Ontario climate: Must work in all weather conditions
• Portability: Stick welders are lighter and more portable for field work
• Inspection standards: MTO and municipal specs often written around Stick welding

Residential and custom fabrication work:

Scenario: Gates, railings, decorative iron work, fences, pergolas.

Recommended method: MIG for production, TIG for high-end work

• MIG advantage: Fast completion for standard gates and fences
• TIG advantage: Clean welds for visible architectural metalwork
• Cost split: MIG saves 30-50% on labor for basic work
• Quality difference: TIG justified for luxury homes and showcase projects

Our experience: Custom metal fabrication in areas like Forest Hill and Rosedale often requires TIG for aesthetic reasons, while standard residential work in suburban GTA uses cost-effective MIG.

Agriculture and Rural Ontario

Farm equipment repair (across rural Ontario):

Scenario: Cracked plow frames, broken bucket teeth, trailer repairs, structural steel.

Recommended method: Stick welding ✅✅✅

• Why: Equipment is dirty, rusty, and often thick steel
• Mobile requirement: We bring Stick equipment to farm sites
• Weather tolerance: Repairs happen outdoors year-round
• Cost efficiency: Stick is most economical for farm repairs

Ontario agricultural reality: Farmers across Peel, Wellington, and Durham regions rely on Stick welding’s versatility and tolerance for less-than-ideal conditions. Our mobile service saves farmers transportation costs and equipment downtime.

Making the Right Decision: A Practical Selection Framework

Rather than memorizing technical specs, use this decision tree based on actual Ontario project variables.

Step 1: Identify Your Primary Project Constraint

If SPEED is your priority: → Choose MIG welding

• Example: Production manufacturing in Hamilton needs 500 brackets welded per day
• Why: MIG’s continuous wire feed is 50-75% faster than alternatives
• Cost impact: Labor savings typically offset higher material costs

If QUALITY/APPEARANCE is your priority: → Choose TIG welding

• Example: High-end Toronto restaurant needs visible stainless steel work
• Why: TIG produces clean, smooth, professional-looking welds
• Cost acceptance: Clients willingly pay 40-60% more for TIG appearance

If DURABILITY/PENETRATION is your priority: → Choose Stick welding

• Example: Structural beam repair for Brampton warehouse
• Why: Stick provides deep penetration into thick steel
• Ontario advantage: Works on rusty or painted existing structures

If COST is your priority: → Choose MIG for thin materials, Stick for thick materials

• MIG for: Sheet metal, automotive work, production fabrication
• Stick for: Structural steel, outdoor repairs, contaminated surfaces
• Avoid: TIG unless absolutely required (always highest labor cost)

Step 2: Assess Your Material

Material Decision Matrix:

Step 3: Consider Environmental Factors

Indoor controlled environment:

• All methods suitable → choose based on cost and speed
• MIG preferred for production work
• TIG preferred for precision and appearance

Outdoor or construction site:

• Stick is your only reliable option for typical Ontario weather
• MIG requires windbreaks and dry conditions
• TIG nearly impossible in field conditions

Ontario winter (below -10°C):

• Stick welding most reliable
• MIG possible with preheating and sheltered area
• TIG requires climate-controlled environment

Step 4: Factor in Labor and Timeline

Tight deadline (project must finish quickly):

• MIG welding if conditions allow
• More welders available = easier to scale up crew
• Ontario reality: Can usually find MIG welders within 2-3 days

Standard timeline:

• Choose best method for application
• Balance cost vs. quality vs. schedule

Extended timeline with quality focus:

• TIG becomes more viable
• Labor cost spread over longer period
• Worth investing in premium result

Labor availability concerns:

• TIG welders: Require 1-3 weeks lead time in Ontario
• MIG welders: Usually available within days
• Stick welders: Good availability in construction sector

Step 5: Calculate True Total Cost

Don’t just compare hourly welding rates—calculate complete project cost:

Formula: Total Cost = (Labor Hours × Rate) + Materials + Consumables + (Cleanup/Finishing Hours × Rate) + (Downtime Cost if applicable)

Example: Toronto restaurant stainless sink repair

MIG option:

• 2 hours welding × $75/hr = $150
• Materials and gas = $40
• 1 hour grinding/finishing = $75
• Total: $265
• Quality: Acceptable but may show slight discoloration

TIG option:

• 3 hours welding × $90/hr = $270
• Materials and gas = $60
• 0.5 hour minimal finishing = $45
• Total: $375
• Quality: Perfect sanitary weld meeting health codes

Decision: TIG’s extra $110 cost is justified because health inspector approval is non-negotiable. Failed inspection costs far more than premium welding method.

RS Mobile Welding Service: Your Ontario Welding Partner

With over 21 years serving Toronto and the Greater Toronto Area, we’ve completed thousands of projects across industrial, commercial, and residential sectors. Our CWB-certified welders bring expertise in all three major welding methods—MIG, TIG, and Stick—along with specialized capabilities in stainless steel, aluminum, and plastic welding.

Service areas: Toronto, Mississauga, Brampton, Vaughan, Markham, Richmond Hill, Ajax, Pickering, Oakville, Burlington, Hamilton, and throughout the Greater Toronto Area.

Ready to discuss your project?

• Call: (416) 825-2956
• Email: rs.welding@hotmail.com
• Visit: 11 Steinway Boulevard, Unit 15, Etobicoke, ON M9W 6S9

Whether you need quick mobile repair, certified structural welding, or precision TIG fabrication, our team delivers the right welding solution for your Ontario project—on time, on budget, and built to last.

Frequently Asked Questions

Which welding method is strongest?

All three methods can produce equally strong welds when properly executed. The key is matching the right process to your material and application. In our Ontario projects, TIG welds consistently test strongest on aluminum and stainless steel due to superior penetration and minimal contamination.

Stick welding produces the strongest welds on thick structural steel. MIG welding strength equals the others on thin to medium steel when done correctly. The welder’s skill matters more than the method itself.

Can I use MIG welding outdoors in Ontario?

MIG welding outdoors is possible but challenging in Ontario’s typical conditions. Wind above 5-8 mph (common across the GTA) blows away the shielding gas, causing porous, weak welds. We successfully use MIG outdoors only with windscreens and on calm days.

For typical Ontario construction sites, Stick welding is the reliable outdoor choice. If your project requires outdoor welding—like fence installation or building repairs—Stick handles wind, light rain, and temperature fluctuations far better than MIG.

Is TIG welding worth the extra cost for my project?

TIG justifies its 40-60% higher labor cost when you need superior appearance, are working with stainless steel or aluminum, require welds meeting food-grade sanitary standards, or are fabricating thin materials under 1/8″ thick.

For Toronto restaurant equipment, pharmaceutical facilities, or high-end architectural work, TIG is mandatory. For standard structural steel or production fabrication, MIG or Stick saves money without sacrificing strength. Our recommendation: choose TIG when the finished weld will be visible or when material/application demands it.

How much does professional welding cost in Ontario?

Professional welding rates across the GTA typically range from $75-$150 per hour depending on the process, certification requirements, and service type. General MIG welding runs $75-$100/hour. Specialized TIG welding or certified structural work costs $100-$150/hour. Mobile/on-site services add $50-$100 trip charge.

Our mobile welding services start at $150 minimum for simple repairs, with typical projects ranging $300-$2,000 depending on complexity and duration. Emergency service carries premium rates but saves costly downtime.

What welding method works best in cold Ontario winters?

Stick welding is the most reliable choice for cold weather work across Ontario. It tolerates temperatures from -30°C to +40°C with minimal equipment issues and works outdoors despite wind and light precipitation.

MIG welding in winter requires preheating the base metal, sheltered work areas, and special attention to prevent wire feeding problems in extreme cold.

TIG welding essentially requires indoor, climate-controlled conditions during Ontario winters. For agricultural equipment repairs, construction projects, and emergency outdoor work from November through March, Stick is our primary method.

Do I need certified welding for residential projects in Ontario?

Ontario Building Code requires CWB-certified welding for any structural or load-bearing applications, including deck railings, stairs, beam repairs, and building supports. Decorative work like garden gates, artwork, or non-structural furniture doesn’t require certification.

If your project needs a building permit, it requires certified welding. Property insurance may also require certification for structural repairs. Our CWB W47.1 certification ensures residential work passes inspection and meets insurance requirements.

Can the same welder do MIG, TIG, and Stick welding?

Many professional welders have basic competency in all three methods, but true expertise usually focuses on one or two processes. At RS Mobile Welding, our team includes specialists in each method—we assign the right welder based on your specific project.

A welder skilled in production MIG work may struggle with precision TIG aluminum welding, while an excellent TIG welder may not have the field experience for rough Stick welding on construction sites. When hiring, ask about specific experience with your material and application, not just general welding certification.