What Is The Difference Between Flux Core And Mig Welding?

Welding is integral technology that is relied on to join a wide variety of metals, but the choice of welding technique is equally as important – and understanding the differences between them is even more so. In this article, we’re exploring the differences between flux-core and MIG welding, which are two of the most popular arc welding processes out there today. With their use in industrial settings increasing rapidly, it is estimated that approximately 10 million metric tons of welding consumables are expected to be used by 202

Understanding the differences between these two methods of welding better can help you make the right decision for your individual needs. So let’s get started – what is the difference between flux core and mig welding?

What is the Difference Between Flux Core and MIG Welding?

MIG and Flux Core welding are two of the most commonly used welding types.

The two processes offer unique advantages and disadvantages that make them suitable for different projects. Understanding the differences between the two will help you select the best welding type for your project requirements.

MIG welding process

MIG (metal inert gas) welding is a process that uses a consumable electrode wire to feed material into the weld joint.

The electrode is housed in a spool and is fed from a vehicle mounted on the welding gun. An inert gas, such as argon or helium, is then used to protect the welding area from oxidation. As the wire melts, it creates a continuous, uniform welding zone.

This method of welding is preferred for thin metals, aluminium and stainless steel.

Flux core welding process

Flux core welding (FCAW) is a process that utilises a consumable wire electrode with a flux core.

The flux core is a powdered material encased inside the wire and acts to shield the weld by producing a gas that forms a protective shielding. This process is primarily designed for outdoor welding operations, as it can be used with or without an external shielding gas.

FCAW is suitable for thicker, multi-layer materials, such as stainless alloys and other ferrous materials.

Advantages & Disadvantages of MIG & Flux Core welding

  • MIG Welding
    • The weld speed is the fastest of all processes.
    • Best for welding nonferrous metals such as aluminium.

    • Good welding quality.
    • Relatively high cost of consumables.
    • More difficult to learn than other processes.
  • Flux Core Welding
    • Can be used with or without an external shielding gas.
    • The flux core provides protection, making it suitable for outdoor welding.
    • Flux core wires can be used for thicker and multi-layer materials.
    • Porosity is higher because the flux core is consumed during the welding process.
    • The wire feeding is inconsistent and the weld pool is not uniform.


MIG and Flux Core welding are both reliable and efficient ways to join metals. The choice between the two depends on the metal type, thickness and the welding environment. MIG welding offers a fast welding speed with good weld quality, while Flux Core welding is more suitable for thicker multi-layer materials and outdoor welding projects. Citation URL: https://weldingtopics. com/what-is-the-difference-between-flux-core-and-mig-welding/ https://www. orangeaviation. com/blog/mig-vs-flux-core-welding

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