Stick, MIG & TIG Welding Basics

Arc welding joins metal using an electric arc that reaches several thousand degrees. Stick, MIG and TIG are the three processes you’ll meet most often. They share core hazards (arc light, heat, fume, electric shock and fire) and each has its own twists. Knowing the differences helps you set up, protect yourself and avoid the common injuries.

• Welders
• Fabricators
• Maintenance
• Apprentices

The three processes at a glance

OSHA’s welding rules apply: 29 CFR 1910 Subpart Q for general industry and 1926 Subpart J for construction. See Welding & Cutting. ANSI/ASC Z49.1 (Safety in Welding, Cutting, and Allied Processes) is the widely used industry guide, and AWS offers training. See AWS Welding Codes.

Hazards common to all arc welding

• Arc radiation: ultraviolet and infrared light burn skin and eyes. “Arc eye” (welder’s flash) feels like sand in the eyes hours after exposure. Light reflects, so people nearby are at risk. See Welding Helmets and Welding Screens.
• Fume and gases: metal fume, ozone and nitrogen oxides, and fumes from coatings (galvanized, painted, cadmium, lead, chromium). See Galvanized Metal Fume Fever, Welding Fume & Manganese and Hexavalent Chromium.
• Electric shock: especially in wet, hot or confined places, and when changing electrodes. See Electrical Hazards Basics.
• Fire and explosion: sparks and spatter ignite combustibles, flammable vapors and dust. See Hot Work Permits and Fire Blankets & Spark Containment.
• Burns: hot metal, spatter and slag.
• Noise, awkward postures and cylinder hazards. See Compressed Gas Cylinders.

PPE for all three processes

• Welding helmet with the right lens shade. As a rough guide, stick, MIG and flux-cored work typically uses shade 10 to 14, and TIG generally 9 to 14 depending on current. Auto-darkening lenses must be rated for the process (especially low-amp TIG). Follow the lens shade tables in the standard. Wear safety glasses under the helmet.
• Flame-resistant clothing and leathers: long sleeves, no cuffs, buttoned collar, FR jacket or leather sleeves and apron, pants over boots, and no synthetic fabric. See Welding Leathers and Flame-Resistant Clothing.
• Welding gloves that are dry and in good condition. TIG welders often use thinner, more flexible gloves because of the dexterity needed. See Hand Protection.
• Leather boots, hearing protection if noisy, and a cap or hood. Use a respirator when ventilation can’t control fumes. See Respiratory Protection.

Process-specific safety

Stick welding

• Keep electrodes dry, since damp low-hydrogen rods cause weld problems and a hazard, and store them as the maker says.
• Don’t touch the bare electrode or the holder’s metal parts with the circuit on, especially when sweating or in a wet area. Wear dry gloves and insulate yourself from the work and the ground.
• Chip slag with eye and face protection, since it flies off hot, and watch for others nearby.
• Handle stubs and hot rods carefully, and put them in a metal bucket, not on the floor where someone can slip.

MIG welding

• Keep hands and clothing away from the wire feed rolls. Pinch points can injure fingers. Release tension and shut off the feeder when adjusting.
• Don’t point the gun at yourself, and don’t put your hand in front of the tip. The wire can pierce skin when fed.
• Avoid drafts that blow away shielding gas and cause porosity, but don’t block ventilation that carries fume away from you.
• Secure the shielding gas cylinder, cap it when moving, and use the right regulator and hoses. See Flashback Arrestors for fuel-gas torches.

TIG welding

• Expect intense UV light, which is stronger without visible smoke. Cover all skin, including neck and wrists, to avoid arc burns.
• High-frequency starting can interfere with electronics and gives a shock if equipment is damaged. Keep leads and torches in good condition.
• Tungsten electrodes: thoriated tungsten contains low-level radioactive thorium. Grinding creates dust, so use local exhaust, wet methods or switch to thorium-free types (such as lanthanated, ceriated or zirconiated tungsten). Wash hands after handling.
• Argon and helium displace oxygen. In tanks, pipes and other confined spaces, ventilate and monitor the air. See Inert Gas Asphyxiation and Confined Spaces.
• Avoid touching the tungsten to the base metal when starting, to prevent contamination and spatter. Use a foot pedal or torch control smoothly.

Equipment and setup safety

• Inspect leads, cables, connectors, clamps and insulation before use. Replace damaged cables and keep connections tight. See Welding Leads & Cable Care.
• Connect the work clamp to the workpiece, close to the weld, and never to pipes, scaffolds, rigging or conduit that could carry current elsewhere.
• Ground the machine and use equipment rated for the power supply. Keep machines dry, and shut them off when not in use.
• Ventilate and use local exhaust, such as fume extractors or fume guns, especially in enclosed areas and for stainless, galvanized or coated metal. See Ventilation.
• Remove combustibles and check the area before welding, and keep a fire watch and extinguisher. See Sparks & Fire Risk.
• Clean the metal: remove paint, coatings, oil and solvents before welding, because heated solvents (such as degreasers) can form toxic gases. Never weld on closed containers that held flammable materials. See Drums & Tanks: Hot Work.
• Protect others with screens and signs. See Welding Screens.

Welding basics checklist

• I wear a helmet with the right shade, safety glasses, FR clothing, dry gloves and boots
• I inspect leads, clamps and the machine; the work clamp is on the workpiece
• Fume is controlled by local exhaust or ventilation, with a respirator where needed
• Combustibles are removed or covered, and a fire watch and extinguisher are ready
• Cylinders are secured and capped; I watch for argon in tight spaces
• I know the specific hazards of my process: slag (stick), wire feed (MIG), UV and tungsten dust (TIG)

Last updated: October 5, 2026