MIG welding Travel Speed compared to 
Stick Welding

Wire fed welding processes like short circuit mig, spray mig, and dual shield flux core have very wide ranges of travel speeds.

Stick welding, while a very good welding process, has a much narrower range of travel speed.

Stick welding excels outdoors, for pipe welding, and one off welds or repairs.

But for production, wire fed processes can make you a lot more money.

Especially bare wire where this is no slag to chip and almost no cleanup.

How Travel Speed Can Be Much Faster with Wire Fed Welding Processes Like GMAW aka MIG Than with SMAW aka stick welding.

In the world of welding, travel speed is often a critical factor that can impact efficiency, productivity, and overall project timelines.

Among the various welding methods, Gas Metal Arc Welding (GMAW) and Shielded Metal Arc Welding (SMAW) are two widely used processes. However, when it comes to travel speed, GMAW can be much greater than SMAW.

Let's dive into why wire-fed welding processes like GMAW can be much faster than traditional methods such as SMAW.

Understanding Welding Processes 

What is GMAW (Gas Metal Arc Welding)? 

GMAW, commonly known as MIG (Metal Inert Gas) welding, involves feeding a continuous wire electrode through a welding gun while an inert gas shields the weld pool from contaminants. This process is favored for its speed and efficiency, making it a go-to choice for many industrial applications.

What is SMAW (Shielded Metal Arc Welding)? 

SMAW, or stick welding, uses a consumable electrode coated with a flux to lay the weld. An electric current passes through the electrode, creating an arc between it and the metals being joined. This method is more traditional and often used in construction and repair work due to its simplicity, portability and ability to weld outdoors and without shielding gas.

Technical Differences Between GMAW and SMAW 

 Equipment and Setup 

GMAW setups typically involve a welding machine, wire feeder, and gas supply. The wire feeder continuously supplies the electrode, making the process smoother and faster. In contrast, SMAW setups are more straightforward but require frequent electrode changes, which slows down the process.

 Electrode Types 

GMAW uses a continuous wire electrode, while SMAW employs individual stick electrodes. The continuous feed of GMAW minimizes interruptions, enhancing travel speed and efficiency.

 Travel Speed in Welding 

 Definition and Importance 

Travel speed refers to the rate at which the welding torch or electrode is moved along the joint. Faster travel speeds mean shorter welding times, and can also result in lower heat input. For some metals, a lower heat input maintains mechanical properties like strength and toughness.

Travel speed of the welding processes greatly affects  large-scale industrial projects where time equals money.

 Factors Affecting Travel Speed 

Several factors influence travel speed, including the type of welding process, the skill of the operator, and the material being welded. GMAW's continuous wire feed and reduced need for electrode changes make it inherently faster than SMAW.

GMAW processes like short circuit mig and spray transfer mig have very large windows of adjustability and therefore have very wide ranges of travel speed for flat and horizontal welding.

Dual shield flux core welding has the ability to have a very fast travel speed even on vertical uphill welding.

 Why GMAW Offers Faster Travel Speed 

 Continuous Wire Feed Mechanism 

The key to GMAW's speed lies in its continuous wire feed mechanism. Unlike SMAW, which requires frequent stopping to replace consumed electrodes, GMAW's wire feed keeps the process moving without interruptions.

 Reduced Need for Electrode Changes 

Electrode changes in SMAW are not only time-consuming but also disrupt the welding rhythm. GMAW eliminates this issue with its continuous wire, significantly boosting travel speed and overall productivity.

 Consistent Arc Length 

Maintaining a consistent arc length is crucial for high-quality welds. GMAW's automated wire feed helps maintain this consistency, whereas SMAW relies heavily on the operator's skill, which can lead to variations and slower speeds.

 Efficiency and Productivity Gains with GMAW 

 Time Savings 

With GMAW, the time savings are substantial. Continuous operation without the need to stop for electrode changes means more work can be completed in less time, translating to higher efficiency.

 Reduced Labor Costs Faster travel speeds with GMAW also lead to reduced labor costs. Less time spent on welding means lower labor expenses, making GMAW a cost-effective solution for many industries.

 Improved Workflow 

The seamless nature of GMAW's operation improves workflow, reducing downtime and increasing overall project efficiency. This is especially beneficial in fast-paced industrial environments where time is of the essence.

 Quality of Welds: GMAW vs. SMAW 

 Consistency in Weld Quality GMAW's continuous wire feed ensures a more consistent weld quality compared to SMAW. This consistency reduces the likelihood of defects and rework, leading to higher overall quality.

 Defects and Rework Rates 

The chances of defects and the need for rework are lower with GMAW due to its steady and continuous process. SMAW, on the other hand, can suffer from defects caused by variations in arc length and electrode changes.

 Aesthetic Aspects 

GMAW typically produces cleaner and more aesthetically pleasing welds. The continuous arc and controlled environment reduce spatter and other imperfections that are more common with SMAW.

 Practical Applications and Case Studies 

 Automotive Industry 

In the automotive industry, speed and precision are crucial. GMAW is widely used for its ability to produce high-quality welds quickly, which is essential for meeting production deadlines and maintaining quality standards.

 Shipbuilding Shipbuilding involves welding large sections of metal, where GMAW's fast travel speed can significantly reduce production times. Its ability to produce consistent, high-quality welds makes it ideal for this industry.

 Construction 

In construction, where structural integrity is paramount, GMAW's speed and quality advantages make it a preferred choice. Its ability to handle various metals and produce reliable welds quickly enhances overall project efficiency.

 Challenges and Considerations 

 Initial Cost of Equipment 

One of the challenges of GMAW is the higher initial cost of equipment compared to SMAW. However, the long-term benefits in terms of speed and efficiency often outweigh these initial expenses.

 Maintenance and Operational Costs 

GMAW equipment requires regular maintenance to ensure optimal performance. While this can add to operational costs, the efficiency gains typically offset these expenses.

 Skill Level Required 

Although GMAW can be easier to learn due to its automated nature, achieving proficiency still requires training. Operators must be skilled in setting up and maintaining the equipment to maximize the process's benefits.

Comparative Analysis: GMAW vs. SMAW in Different Industries

Industry-Specific Benefits

Different industries may prioritize various aspects of welding. For example, the automotive industry values speed and precision, making GMAW ideal, while construction might favor SMAW for its simplicity and lower initial costs.

Real-World Performance Data

Studies and case studies often show that GMAW outperforms SMAW in terms of speed and efficiency. Real-world data from industries like automotive and shipbuilding highlight these advantages, reinforcing GMAW's superiority in many applications.

Future Trends in Welding Technology

Automation and Robotics

The future of welding is likely to see increased automation and the use of robotics...especially cobots, further enhancing the speed and precision of processes like GMAW. These advancements will continue to push the boundaries of what is possible in welding technology.