Which welding method costs more between TIG vs MIG welding? While both allow joining metal and laser cut machining parts, they differ in important ways. If you want to budget your welding project expenses better, you must have a clear idea about the cost breakdown.

TIG welding is generally more expensive than MIG welding. Not only is the service pricier, but the slower welding process of TIG means projects take longer to complete, leading to increased costs compared to faster MIG technique.

Read on to learn more about the key differences between TIG and MIG welding cost factors. Understanding where expenses occur with each method will help you choose the most cost-effective solution for your specific welding needs. 

TIG Welding Cost Breakdown

TIG welding is a useful technique for joining metals precisely, like precision machining parts. It’s also more expensive than other common welding methods. 

We’ll explain the different costs involved with this welding technique. Find out if TIG is the right choice for your project. 

Initial Investment Cost

You have to buy welding gear before you can start a project. This includes a welding machine, torch, gas tank, regulators, and other small things. It’s different from other costs because you have to spend it up front.

The money you put in at first varies a lot based on what kind of welding you need. A simple machine with an attachment might work if your projects are not complex. But bigger welding jobs require more advanced gear. A robotic arm and computer controlled power source costs a lot more.

What gear is best depends on what you will use it for. Building simple stuff at home costs less than work for a factory. There are many options between basic and robotic welding.

Labor Cost

The labor cost includes how long it takes workers to complete a welding job. TIG welding normally takes more time than other welding methods. The worker has to carefully set up everything and change the filler rods, along with preheating parts sometimes.

How fast the welding deposition rate and travel speed are also affects labor costs. The quicker a weld can get done, the more jobs the workers can finish per day. 

With TIG welding, the travel speeds are often slower than other methods. This means it takes longer to complete welds. The slower the welding goes, the higher the labor costs become as a percentage of the total cost for the job. 

In the end, the labor costs are a large part of a project’s total price tag. 

Filler Metal Cost

When doing a welding project, you need to use electrodes or filler wire to make the weld. There are a few things that affect how much the filler metal will cost you.

• The amount you need depends on the size of the weld. Bigger welds take more filler metal. Smaller welds don’t use as much. 
• You have to know what each electrode or spool of wire costs. Some filler metals are cheaper than others.
• The amount of the filler metal actually gets used to make the weld. With TIG welding, almost no wire is wasted through sparks or leftover ends like with other welding methods. This makes filler wire costs very predictable for TIG jobs.

Another cost is replacing the tungsten electrode over time as it wears down from current use. Welders also occasionally need new torch nozzles that guide the electrode and gas. 

Shielding Gas Cost

TIG vs MIG welding cost differences for shielding gas depends on the type of gas used, how fast you use it, and how long your welds take. 

It’s a good idea to do some estimation beforehand. Think about how many welds your project has and how long each might take. Then, research average gas flow rates and current pricing. 

In this way, you can keep the gas expenses within your budget. Proper planning is important since gasses are a recurring expense every time you fire up the torch.

Electric Power Cost

The more welding you do, the more electric power you use. 

How much electricity welding takes depends on a few things. The welding current and voltage decide how much juice is needed. A machine’s efficiency matters too. Some machines waste less power than others. Welding for longer times means using more power over all. Finally, what the electric company charges per unit of power affects the price.

While electricity is just a small part of welding costs usually, it can become higher on big jobs. The more welding required by a project, the more the power bill adds up. 

So, for large welding jobs, keeping track of electricity costs helps get an accurate total cost estimate. It’s one more thing welders need to factor into their quotes.

The Final Cost Is…

If you’re thinking of getting into TIG welding, it’s important to understand the total costs involved. While machines can range widely in price, there are several other expenses to factor in for a complete TIG welding setup.

A TIG welding machine can cost anywhere from $500 for a basic manual model up to $5,000 or more for a fully-featured professional unit. The quality and features of the welder will determine where it falls in that price range.

In addition to the welder, a setup needs a few more essential accessories. A gas regulator and torch are must-haves to supply the inert gas needed for TIG. You’ll also need consumable tungsten electrodes and filler rods. Altogether, plan on spending $500-$2,500 for a basic setup that includes the welder, gas equipment, and consumables.

Don’t forget about safety gear either. At minimum, you’ll need a welding helmet, gloves, and clothing to protect yourself from UV rays and sparks. Higher-quality gear can bump your initial costs higher.

Once you have your setup, ongoing costs include replacement electrodes, filler material and shielding gas. TIG welding also tends to be slower than other methods. This means projects will take more time, 

On the other hand, if you’re thinking of hiring a professional for your project, expect to pay around $75 to $125 per hour. The total cost can be different if you take services or welded products from a company. 

MIG Welding Cost Breakdown

MIG welding is one of the most affordable welding methods that allows people to work with different types of metal. The method is best suited for repairing automotive parts, custom metal fabrications, and many other tasks. 

The expenses come mainly from buying the welding equipment and gas. Let’s get the breakdown: 

Initial Investment Cost

The MIG vs TIG setup components are almost similar but their prices vary. The cost depends on how automatic your setup is. A semi-automatic welding station is cheaper than a fully automatic one.

Your budget also depends on what kind of welding work you need to do. Semi-automatic gas metal arc welding is a good choice when you need to weld a lot of pieces quickly. It’s faster than welding by hand. But you still need to move the gun yourself.

The equipment for MIG welding doesn’t cost as much as other welding methods, like plasma cutting or TIG welding. The skills needed are easier to learn too compared to welding with a stick electrode or gas torch.

This makes MIG welding a good option when you’re just starting out. It allows you to produce consistent welds without needing years of experience. 

Labor Cost

The labor cost of TIG vs MIG welding jobs are not the same, with the latter costing less. 

How much time a welder spends on each job affects these labor costs. If a welder has to guide the welding gun by hand for every part, it takes more time than if a machine can do more of the work itself.

Welding jobs where welders have to move the gun by hand are called semi-automatic welding. In these jobs, the welder usually spends between 25% to 60% of the total time working. The rest of the time the welder sets things up or does other tasks. It could be only 20% of the working time when using an automatic machine. 

The faster a welder can complete a welding project, the lower the labor costs will be. Things like how fast the welding wire lays down metal and how quickly the welding gun can move affect productivity. Different materials like steel thickness also impact speeds and times.

Changing settings, such as wire size, welding current, or travel speed can help boost productivity and lower labor costs. In a word, minimizing welder hands-on time as much as automation allows cuts down on welding labor expenses.

Electrode Cost

Several elements contribute to the overall electrode cost. Firstly, the weight of metal deposited during each weld directly affects how much electrode is used. Heavier deposits mean more wire is consumed.

The type of electrode also influences costs. Thinner solid wires tend to be pricier per pound compared to thicker versions or flux-cored options. Purchasing in bulk lowers the per-pound price. Also, choosing large reels over small coils is more affordable. Of course, the total quantity needed matters as well. Bigger orders usually have reduced rates.

About 5% of the electrode is lost to spatter and vaporization during welding. This deposition efficiency varies a bit with shielding gas. Argon creates less sputtering than carbon dioxide, so it preserves more of the wire. 

Shielding Gas Cost

There are a few things that affect how much you pay for the gas. 

• The type of gas. The most commonly used shielding gas in MIG welding is argon. It’s also the cheapest. You can use helium too but it costs way more. 
• Flow rate. Some welders use more gas than others. A high flow rate means you go through the tank quicker.
• The duration of the task. Shorter jobs don’t use as much gas as longer jobs.

Electric Power Cost

The cost for TIG vs MIG welding electric power use is the same. It only differs by the welding time, the amount of welding current and voltage, and the price of electricity. 

What amps does your MIG welding machine use when welding? The higher the amps, the more power it takes. You also need to know the voltage. Then, find out how long your welds typically are. Welding for an hour uses more power than welding for 15 minutes. You can calculate the total cost by factoring in all the aspects. 

The Final Cost Is…

The total cost of a MIG welding setup includes more than just the welder machine. You’ll need welding wire, a gas tank and regulator, safety gear, and other accessories. All together this can add up quickly.

A basic MIG welder will cost $300 to $800, depending on features. You’ll need protective gear like a helmet, gloves, and jacket. You may also want a welding cart, clamps, grinder, and other tools. All of these “extras” can easily add another $500 or more to your setup costs.

For most home and small shop projects, plan on spending $800-$1500 to get started with a fully equipped but basic MIG welding system. Larger, more powerful machines and advanced accessories drive costs even higher. 

Professional services typically cost $65 to $90 per hour. And if your company needs welded components from a manufacturer, the price could be determined based on different factors, like quantity of parts, complexity of the welding work, and other things. 

Contrast Table of TIG vs MIG Welding Cost Differences

The costs of TIG and MIG welding can vary a lot. So, we’ve made a table comparing their differences that could be helpful for your welding project budgeting. 

TIG welding is usually chosen for higher quality welds or thicker materials, not just cost savings. MIG welding might be cheaper for the right jobs. 

TIG vs MIG Welding Cost Comparison Table

Conclusion

Comparing TIG vs MIG welding, the first option tends to cost more money for most welding projects. The extra skills and time needed for TIG means it costs more to do. MIG welding can put metal down faster so jobs get done quicker. Many metal fabricating shops pick MIG for its better value. But TIG makes nicer-looking welds needed for things like artwork or fixes on expensive machines. So, for quality, TIG is worth the higher price.

Do you have welding jobs that demand quality results? Then, contact the pros at Zintilon. We offer welding services for components made with sheet metal fabrications and advanced precision machining. Get in touch for an estimate on your next welding project. 

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