MIG Welding
Automated MIG (Metal Inert Gas / GMAW) cells deliver consistent, high-speed welds for production enclosures and brackets. MIG deposits 2–3× faster than TIG with excellent fusion depth, making it the process of choice for structural joints on carbon steel, stainless, and aluminum. We achieve continuous fluid-tight seams that enable IP65-rated enclosures, backed by X-ray inspection on critical assemblies.
MIG welding feeds a consumable wire electrode through a shielding gas to join sheet metal continuously. It deposits metal faster than TIG and tolerates looser fit-up, which makes it the most economical process for structural steel frames, brackets and thicker plate where the seam is functional rather than cosmetic.
What thickness does MIG welding need?
MIG works best from about 1.5 mm upward. Below that the heat input tends to burn through or warp the sheet, and TIG or laser welding gives a better result. On 3 mm and thicker plate, MIG is both faster and cheaper per metre of weld than any alternative we run.
How much distortion should I expect?
More than with TIG, because MIG puts more heat into the part. We control it with balanced weld sequences, tacking and fixturing, and by welding in short runs with cooling pauses on long seams. For frames that must stay square we weld in a jig and check geometry before release.
MIG welding: process window on sheet metal
| Parameter | MIG capability | Note |
|---|---|---|
| Practical thickness range | 1.5 mm and up | Below 1.5 mm use TIG or laser |
| Materials | Carbon steel, stainless, aluminium | Wire and gas matched to alloy |
| Penetration | High | Suits load-bearing joints |
| Post-weld dressing | Usually required | Grinding removes spatter and bead profile |
| Relative speed | Fast | Lowest cost per metre on thick plate |
Common questions about MIG Welding
Can MIG welds be powder coated?
Yes, but the seam needs dressing first. MIG leaves spatter and a pronounced bead, both of which show through a coating. We grind the seam, remove spatter, then run the part through the standard pretreatment and powder line so the finish is uniform.
Is MIG strong enough for load-bearing frames?
Yes. With a matched filler wire and correct penetration, a MIG weld is at least as strong as the parent metal on mild steel. For structural frames we confirm joint design and weld size against your load case, and we can supply weld procedure details on request.
Do you weld aluminium with MIG?
We do, using a spool gun or push-pull torch with argon shielding and the correct alloy filler. Aluminium MIG is sensitive to cleanliness and wire feed consistency, so for thin or cosmetic aluminium parts we usually recommend TIG instead.
Materials we run this process on
Related capabilities and next steps
Specifications
Capabilities
MIG vs Other Welding Methods
Multi-parameter comparison to help you choose the right joining method for your application.
| Parameter | MIG (GMAW) | TIG (GTAW) | Spot (RSW) | Laser |
|---|---|---|---|---|
| Welding Speed | Moderate — 1000–3000 mm/min | Slow — manual pace, 50–300 mm/min | Very fast — 0.1–0.5 s/spot | Very fast — 10–5000 mm/min |
| HAZ Width | Moderate — 3–5 mm | Narrow — 1–2 mm | Very narrow — <1 mm | Ultra-narrow — <1 mm |
| Distortion | Moderate | Low | Very low | Minimal |
| Filler Material | Required | Optional | None | None |
| Automation | Semi-auto / auto | Manual / semi-auto | Fully automated | Fully automated |
| Appearance | Good — minor ripples | Excellent — smooth stacked-dime bead | Limited — spot marks only | Excellent — cosmetic seam |
| Best For | High-speed structural welds | Food-grade, sanitary, visible joints | High-volume sheet assemblies | Precision enclosures, thin-wall parts |
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