You’ve probably heard of MIG welding before. It's one of the most common welding processes.

But what about MAG welding? MIG and MAG are actually two distinct processes, where MAG welding uses an active gas, and MIG welding uses an inert gas. Sounds like a tiny difference, but it affects penetration, for example.

In this article, we'll break down exactly what MAG welding is, how it works, and how it differs from MIG welding.

We’ll cover: 

• What is MAG welding, and how does it work? 
• Best practices
• An overview of MAG vs. MIG Welding
• MAG welding cases in several industries
• Whether you can automate MAG welding
• Common issues and safety considerations

Let’s dive right in! 

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What is MAG welding, and how does it work?

MAG welding, or metal active gas welding, is a type of arc welding that uses an active shielding gas like carbon dioxide or argon to protect the weld pool from atmospheric gases. 

The shielding gas plays an active role in the welding process, chemically reacting with the molten weld pool.

The key is an electric arc that forms between a wire electrode with a continuous feed and the base material. The heat of the arc melts the wire and the base material, fusing them together. 

Here’s how the magic happens: 

1. Shielding gas magic! The shielding gas goes through the gun to protect the weld pool from contamination. Argon and carbon dioxide are commonly used — the gas shields both the molten weld pool and the arc from the air.
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2. All filler, no killer: A wire electrode, typically made of steel, acts as the filler metal. It's continuously fed through the welding gun and into the weld pool. There, it melts and fuses with the base material. As the weld forms, the gun moves along the joint.
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3. Powering things up: A constant voltage power source provides the electrical energy to maintain the arc. The arc, in turn, melts the wire and base material. As the wire is fed through the gun, the arc is kept at a steady voltage.
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4. Shooting from the hip: The weld gun directs the electrode, shielding gas, and arc to the weld joint. A trigger controls the speed at which the wire is fed and the flow of shielding gas. Using the gun, the welder can manipulate and direct the arc and weld pool.

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MAG welding techniques and best practices

MAG welding gets the job done — but only if you nail the setup. From picking the right shielding gas to mastering the correct welding position, minor adjustments can mean the difference between flawless welds and, “Ouch, that’s gonna leave a mark.” 

Here’s how to do it right:

• Proper setup keeps things smooth: Before starting, check wire feed speed, voltage, and torch angle. A clean work surface and the right machine settings prevent weak welds and rework.
  
  
• Shielding gas selection matters: Use CO2 for deep penetration and a stronger weld, or go with an Argon-CO2 mix for cleaner results and reduced spatter. Different materials need different gas combos — don’t guess.
  
  
• Master the right welding position: Flat position is easiest for beginners, while vertical and overhead positions need tighter control. Adjust travel speed and torch angle to prevent drips and uneven welds.

• Choosing the right MAG welding machine saves headaches: Pick a machine that matches your power requirements and offers the right features.
  
  If you’re working with thick materials, a higher-amperage machine like the Lincoln Electric Power Cooper cobot provides enough power and flexibility. Look for models with adjustable wire feed speed, digital displays, and pulse welding capabilities. Stick with good brands, or kick yourself in the teeth later. 

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Understanding GMAW: MIG vs. MAG welding 

In short, MIG stands for metal inert gas welding, while MAG refers to metal active gas welding. 

Both are a subset of GMAW, but what does GMAW stand for? Gas metal arc welding. Here’s a quick snapshot comparison of MIG vs. MAG welding. 

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Let’s dive a bit deeper into the distinctions:

• Different gases for different folks: MIG welding uses inert gases for shielding, such as argon or helium, that do not chemically react with the molten weld pool. MAG welding uses an active shielding gas, typically a mixture of argon and carbon dioxide, that does react with the weld pool. The active gas helps stabilize the arc and gives better weld penetration.
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• Some pros and cons: MAG welding produces welds that tend to be stronger and deeper penetrating than MIG welds, but the final strength of the weld would depend on several factors, including material type and application. Moreover, the reactive shielding gas can lead to more spatter and fumes. MIG welding with an inert gas produces cleaner, spatter-free welds, but may lack the all-around strength and depth of MAG welds.
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• When do you even use each? Use MIG welding when you need an aesthetically pleasing, spatter-free weld, such as welding sheet metal. Conversely, give some thought to MAG welding for welding thicker materials or when weld strength is critical, such as structural welding. Also, MAG welding tends to be a bit more economical since carbon dioxide is less expensive than argon.
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• Automation: Both MIG and MAG welding can be automated using mechanized equipment like welding carriages, boom arms, and welding robots. Automated MAG welding, in particular, is commonly used for high-volume production applications in industries like auto manufacturing.

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MAG welding use cases across diverse industries

You may be saying to yourself, “This is all well and good, but who is using MAG welding in the real world?”

Glad you asked, because we’ve got some real-world use cases for you: 

• Keeping the auto industry together: The auto industry relies heavily on MAG welding for manufacturing vehicle bodies and frames. The high deposition rates and faster travel speeds of MAG welding make it ideal for joining large sections of sheet metal. 
  
  You'll find MAG welds on everything from fenders and doors to chassis and suspensions. From 2025, you’re also likely to find automotive welds completed by cobot TIG welding. 

• Keeping the ship afloat: For similar reasons, shipbuilders frequently use MAG welding. It allows them to join huge steel plates for hulls and decks in a timely and cost-effective manner. The high heat input also produces welds that can withstand the extreme forces experienced in marine environments. 
  
  MAG welding produces the continuous, watertight seams necessary for sea vessels. For instance, P+P Pragma-Tec uses MAG welding processes for continuous hull plate welding and structural assembly in marine vessels. 

• Heavy-duty machinery: The heavy machinery industry depends on MAG welding to build massive components like crane booms, bulldozer blades, and tractor frames. MAG's high deposition rates and penetration are pretty much essential for achieving strong, durable welds on dense, thick materials. 
  
  This is doubly important when manufacturing equipment that will withstand intense strain and loading. Fortaco Group is a prime example of MAG welding in heavy-duty machinery — Fortaco Group uses MAG welding to fabricate crane booms, tractor frames, and wear-resistant steel parts. 
  
  MAG welds are also often used to join dissimilar metals in heavy machinery.

• Building those long pipelines: For constructing long-distance pipelines, MAG welding is the most efficient and productive process available. It can produce the long, continuous seams needed to join sections of pipe. MAG also provides the penetration required for high-pressure, high-temperature applications like oil and gas pipelines. 
  
  Automated MAG welding systems are frequently used in pipeline construction to maximize speed and ensure weld consistency over long lengths. For example, Tekfen Construction (collaborating with MagnaTech) used automated MAG welding for corrosion-resistant alloy (CRA) pipelines in Oman.

• Steel construction: MAG welding is everywhere in steel construction and fabrication. It’s used for joining wide flange beams, channel sections, square and round tubes, and plate girders. MAG produces full penetration welds and minimal distortion, which are essential qualities for load-bearing steel structures. It also allows for high deposition rates and faster travel speeds to maximize productivity. 
  
  You'll find MAG welds in everything from steel-framed office buildings to stadiums, bridges, and towers.

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Can you get an automated MAG welding machine?

Yes. MAG welding can absolutely be automated. In fact, it’s one of the most commonly automated welding processes used in manufacturing today. In fact, Allied Market Research reports that the global robotic welding market was assessed at $5.5 million in 2018 and is anticipated to climb to $10.8 million by 2026, growing at a CAGR of 8.7%. 

Robotic MAG welding, also known as robot welding, offers quite a few benefits over manual welding:

• Productivity gains: Robotic MAG welders can work pretty much forever until they need maintenance, increasing productivity and reducing costs. They are also often faster than human welders, able to complete more welds in less time. Some robotic MAG welders can perform over 100 welds per minute!
  
  Note: A more common range is likely 30–60 welds per minute.
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• Massive quality boost: Robotic MAG welding also provides more consistent, higher-quality welds. Robots can precisely control factors like weld speed, wire feed rate, and arc length to produce uniform welds time after time. They don’t experience issues like tiredness or variation in technique that can affect human welders.
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• Far safer: Automating the MAG welding process also improves safety by removing humans from hazardous conditions like toxic fumes, high heat, and arc radiation. Robot welders can work in confined or awkward spaces where it would be difficult — or dangerous — for humans.
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• Your bank account will love it: Although robotic MAG welding systems have high upfront costs, they can save money in the long run through increased productivity, reduced waste, and less rework. The costs of robotic MAG welder usage have also declined in recent years, making automation more accessible for many manufacturers. Plus, its automation MAG welding has a sweet ROI of just 1–3 years. 

MAG welding isn’t going to be replaced anytime soon. However, depending on your needs, there are also other types of welding worth considering, like robotic TIG welding and resistance welding. 

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What are common issues in MAG welding

Even experienced welders run into problems with MAG welding. Poor weld quality, excessive spatter, and weak penetration are all signs that something’s off.

Here’s what to watch for:

• Porosity that ruins the weld: Improper shielding gas flow or contamination introduces tiny holes in the weld, weakening it.
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• Excessive spatter everywhere: High voltage or incorrect wire feed speeds create too much spatter. Dial in the correct settings to keep cleanup to a minimum.
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• Lack of fusion causing weak joints: Moving too fast or using too little heat results in incomplete fusion between the weld metal and base material.

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Safety considerations in MAG welding

MAG welding isn’t dangerous if you play it smart. Skipping safety steps puts you at risk for burns, fumes, and even electrical hazards.

Here’s how to stay protected:

1. Protective gear that actually works: A flame-resistant jacket, leather gloves, and a properly rated welding helmet protect you from sparks and UV radiation. No shortcuts here.
   
   
2. Ventilation to clear the fumes: Welding fumes contain harmful particles. Proper ventilation or an exhaust system keeps the air clean and your lungs safe.
   
   
3. Equipment maintenance to avoid accidents: Regularly inspect cables, connectors, and gas lines to prevent equipment failure. A faulty machine is an accident waiting to happen.

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Summing up

Those are the key differences between MIG and MAG welding summarized for you. While they share a lot in common, the distinctions around shielding gas and wire feed speed can be important depending on your specific welding application. 

MAG’s versatility and automation potential make it the preferred choice for many industrial settings — although, of course, don’t count MIG welding out completely.

In the end, it’s up to you to assess your budget, application, and potential for growth to assess whether MIG, MAG, and automation are the right fit for your business! 

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Next steps

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• Superior performance benchmarks: With an 18 kg payload and leading speed and precision, RO1 elevates MAG welding operations through its intelligent, self-learning technology comparable to GPT-4 AI. 

• Comprehensive safety measures: RO1 integrates a wide range of sensors and safety features for a safe and efficient MAG welding process in varied operational settings.

• Adaptive learning and improvement: At the cutting edge of automation, RO1 tops the charts in flexibility and continuous self-improvement, optimizing its capabilities with every use. It’s great for a variety of jobs, not just spot welding; it handles pick-and-place, CNC machine tending, and more. 

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