The 10 Best MIG Welders 2023

Complete Guide to MIG Welding

If you’re new to the world of MIG welding, it’s worth doing some research before purchasing one of your own.

These high-tech industrial machines vary widely in features and functions, not to mention the cost. Understanding the basics will help you make a better-informed decision and pinpoint the perfect product for your needs.

But don’t worry; it won’t take long to get up to speed. And to simplify the learning process, we’ve carefully constructed this informative and easy-to-understand buyer’s guide.

What Is MIG Welding?

Let’s start with the basics, shall we?

MIG welding is a commonly used arc welding process, where a solid wire electrode feeds through the welding gun to the welding pool to fuse two metals. MIG stands for “Metal-Inert Gas,” which refers to the inert gas that flows through the welding gun to protect the weld pool from potential contamination. The process is technically known as “gas metal arc welding” (GMAW), or colloquially as “wire welding.”

MIG welding is particularly popular with hobbyists as the process doesn’t require (overly) expensive equipment or specialist training. With rudimentary online research, a competent DIYer could quickly learn the relevant techniques and kick-start a MIG welding project at home.

Although a hit with hobbyists, MIG welding also has a range of industrial applications. Automotive workshops, for example, commonly use MIG welders to repair damaged vehicles and parts.

Flux Compatibility

As we know, MIG welders regulate a flow of inert gas to shield the weld pool. A welding device that lacks this functionality isn’t technically a MIG welder; rather, it’s a flux-core wire feed machine.

Although we’re primarily discussing MIG welders in this guide, many of the top products serve as flux-core welders as well. This method sees a welding flux embedded into the core of the wire. When the wire comes into contact with the arc, it melts the metal and releases flux as a vapor to create a shielding gas.

Ultimately, both methods achieve the same ends: protecting the weld pool from contamination.

The advantage of flux-core welding is you don’t have to hook the welder up to an external gas cylinder. Flux-core welding is also preferable in windy conditions when sudden gusts can disperse the protective gas shield.

On the downside, the flux core creates a fine layer of slag, which you’ll need to chip away for a clean weld—factor extra labor time into each job. Flux-core welding also isn’t appropriate when working with aluminum or stainless steel, which requires a proper Metal-Inert Gas shield.

Ideally, aim for a MIG welder that includes flux-core compatibility. That way, you can switch between the two methods as required—it’s the best of both worlds.

Some highly versatile machines also include TIG and stick compatibility, allowing workers to undertake a wide variety of welding tasks.

Understanding Voltage

In simple terms, voltage refers to the pressure applied to an electrical circuit.

American homes use 120V (technically 114 to 126 volts as there’s often some variation), which is plenty powerful enough to run your everyday appliances. However, for industrial applications such as heavy-duty welding, many workshops install a 240V (variation also applies) system. These take in half as much current and don’t suffer as severely from power loss.

MIG welders are compatible with 120V, 240V, or both. If you’re planning to do all your welding at home, opt for a 120V or a dual voltage device, which will be compatible with any standard residential outlet.

If you’re expecting to weld in specialist workshops, however, then 240V or dual voltage is your best bet—these places often don’t have access to a 120V outlet.

Power Output

More amps mean more raw welding power, enabling you to cut through thicker metal. For example, high-end 120V welders are currently capable of running up to an impressive 140 amps, which is enough to weld 3/8-inch of steel. 240V machines can achieve even higher amp outputs, thus work well for thicker sheets.

The big drawback to a powerful, high-amp welder is the elevated price. You can expect to pay a premium for the privilege of doing thicker welds.

Another downside to consider is the duty cycle. High-intensity welding will heat the unit rather quickly, which means you’ll need to wait longer for it to cool down.

Duty Cycle

The duty cycle refers to how much time you need to spend waiting for your welder to cool off.

The metric is measured as a percentage of a 10-minute period with a specific amp output. For example, a welder with a duty cycle of 30% @ 150A can safely be used for three consecutive minutes on a 150 amp setting. After three minutes, the welder must wait seven minutes for it to cool down.

It’s not a huge concern for hobby welders with stacks of time on their hands. But for production welders seeking to optimize their hourly output, having an efficient duty cycle is essential.

Note that duty cycle figures are measured against a specific amp rating, which isn’t necessarily the maximum output of the welder. If you’ve got a beefy 140 amp machine, for example, the advertised duty cycle of 30% could be rated for a much lower setting, such as 90 amps. Try turning it up to 140 amps, and the duty cycle could drop as low as 10%.

Intense, high-amp welding will reduce the duty cycle, thus entail more waiting time. The top welders include fancy cooling systems such as in-built fans, which improve the duty cycle significantly.

Some even come with thermal overload protection. These prevent accidental damage by automatically switching the welder off once the recommended duty cycle has been reached.

Weight

Weight can be a key consideration when shopping for a MIG welder. If you need to transport your welder around town, it’s essential to opt for a portable model.

Top-end industrial welders can weigh as much as 250 pounds—you certainly don’t want to try lugging those around. Although it’s possible to position such a welder onto a cart with wheels, it’s still going to be rather cumbersome to move. Nonetheless, if you’re happy to permanently leave your welder in the workshop, there’s no harm in having a big, bulky device.

Portable models, on the other hand, can be as light as 20 pounds, thus easy enough to lift into your car or truck.

As you’d expect, high-power options for industrial use tend to be heavier, while low-end MIG welders for home use are typically more portable.

Temperature and Speed Settings

For the novice welder, the ability to control temperature and speed will significantly simplify the welding process. Some MIG Welders, like the Miller Electric MIG are specifically designed to be user-friendly, and these welders are best for beginners.

Most modern MIG welders incorporate a knob or cooling vent to control temperature and speed. If you’re new to MIG welding, it’s worth confirming whether your welder of choice has these features. Not only will this level of control allow you to achieve a cleaner weld, but it will help you avoid nasty accidents too.

Proper MIG Welding Maintenance

Although taking care of a MIG welder is relatively straightforward, there are a few things you should know.

Use a Cover

It’s worth putting a cover over your MIG welder, especially if you’re storing it in a dusty environment. Particle debris can find its way into the delicate mechanical components and cause significant damage over time.

Most manufacturers sell a custom-made cover that fits perfectly over the device.

Clean the Drive Rolls

Regardless of how careful you are to cover your welder, dirt can accumulate on the drive rolls due to the wire that’s continuously fed through them.

Keeping the drive rolls clean is simple enough: either brush them down or blow air over them after each use.

Clean the Contact Tips

Splatter can sometimes stick on the contact tips, which inhibits the gas flow and leaves the bead vulnerable to contamination.

Applying some nozzle dip over the contact tip will stop splatter from adhering to it.

Essential Safety Gear

Even a seasoned professional welder will tell you the process is hazardous without the proper safety gear. Invest in the following items and wear them every time you reach for the welding torch.

Welding Mask

Stray sparks fly everywhere when welding, including straight into your face. What’s more, the welding arc is eye-scorchingly bright, enough to cause permanent damage to your retinas.

A welding mask is a crucial piece of PPE every welder must wear. The top-end options, such as the YESWELDER, come with a fancy auto-darkening feature that lets you quickly see the welding arc and position the torch accordingly.

Welding Gloves

As there are so many hot molten sparks flying around, there’s a good chance some will end up on your hands. The easiest way to protect yourself is by donning a proper pair of welding gloves.

These specially designed accessories are thick enough to provide adequate protection yet nimble enough to let you position the torch. Stacks of competing products are available to choose from—we recommend RAPICCA as a good overall option.

Cotton or Leather Clothing

When welding, you need to cover exposed skin to safeguard yourself from wayward sparks.

A heavy-duty pair of coveralls is your best bet. Failing that, any cotton or leather clothing will do in a pinch. Just make sure you’ve got long-sleeved apparel as you don’t want to scorch your forearms or shins.

Also, avoid wearing synthetic garments like polyester as these will melt and scald your skin.

MIG Welding Accessories

You’re not done shopping just yet.

MIG welding can require a range of accessories, depending on the type of project you’re working on. Consider adding the following items to your welding war chest.

Gas Cylinders

MIG welders require gas to operate and don’t come with a cylinder as part of the package—you’ll need to buy one separately.

The ideal gas depends on your budget and what you plan to weld. Good ol’ carbon dioxide is the most common, a cost-effective option that works well in most welding applications.

Serious welders tend to prefer a CO2 and Argon mix.  Although more expensive, it achieves a better quality result with less splatter than standard CO2.

Another premium option is Pure Argon, which is perfect for welding titanium and magnesium. Avoid using the stuff on ferrous metals, however, including cast iron and alloy steel.

Gas Regulators

In addition to a gas cylinder, you’ll also need to purchase a regulator. Not only does the device help you maintain optimal flow for a nice clean weld, but it also reduces wastage—and that’s crucial when working with the pricier gasses.

Gas regulators come in three types: gaugeless, single gauge, and dual gauge.

Although inexpensive, gaugeless regulators don’t provide any information on flow rates or how much gas remains in the bottle. Single gauge regulators, on the other hand, let you see what you’ve got left and view the current flow rate. Dual gauge regulators offer the above functions and let you set the flow rate according to the gas type.

If you’re working with anything other than CO2, it’s worth investing in a dual gauge regulator.

Spool Gun

A spool gun is a special device that hooks into the torch handle to control the metal movement speed. The add-on is essential when working with aluminum.

Some MIG welders come with a spool gun included as part of the package, but many do not. If you plan to work with aluminum, grab a product with a pre-equipped pool gun or a compatible MIG welder.

Not all MIG welders work with all spool guns, so it’s crucial to double-check these details with the manufacturer beforehand.

MIG Welding FAQ

If you’ve still got questions about MIG welding, take a look through our FAQ.

Should I Buy a MIG or Stick Welder?

Stick welders are more affordable and preferable if you’re working on basic welding projects. But if you’re doing variable welding gigs that require adjustable settings, then a MIG welder is your best bet.

If you’re not sure, you could always get a versatile welder that can do both.

Is Gasless MIG Welding Any Good?

Although MIG welding with gas affords a cleaner weld with less splatter, gasless (flux-core) welding comes with two distinct advantages: there’s no need to acquire a gas cylinder, and you can continue working in windy conditions.

Is TIG Stronger Than MIG?

Tungsten Inert Gas (TIG) welding creates a cleaner and more precise weld than MIG, especially when joining small pieces of metal such as steel wiring. However, MIG welding is preferable in certain situations, such as when you’re working with thick metal.

Is Stick Welding Harder Than MIG?

MIG welding is a much easier process to learn, which is why it’s such a hit with the home improvement crowd. Having said that, once you’ve learned the fundamental techniques behind stick welding, it’s the quicker and easier option as there’s less set up (and pack down) time.

Why Do My MIG Welds Look so Bad?

There’s a wide range of reasons why you’re MIG welds don’t look the part: low wire feed speed, low amperage, and slow travel speed, among others. But don’t give up; with time, you’ll master MIG and start welding like a pro.

The Best MIG Welders: Final Thoughts

MIG welding offers a beginner-friendly entry point for novices plus a high level of performance for the pros. Whether you’re dabbling into the welding world or you’re an established industry veteran, a MIG welder offers the ideal solution for a wide range of projects.

But because these nifty machines cater to so many skill levels and needs, it can be challenging to pinpoint the perfect product.

We’ve done our bit to demystify the technology by providing an in-depth Buyer’s Guide and reviewing the Top 10 Products on the market today.

Take the time to read up on the fundamentals, then start browsing through our recommendations. We’re confident you’ll find a quality MIG welder that’s suitable for your needs.