Flux Cored vs MIG Strength Head to Head Comparison

Checking out flux cored vs MIG strength is a must to get exceptional results from your welding op.

Most folks, particularly the newbies, may believe any method works just fine. It would be best if you had the right welder when you’ve got numerous types of metal at different thicknesses to handle.

Most welders opt for flux cored or MIG welders due to these methods’ high join capability. But to obtain the right weld every time, you’ve got to know each welder’s weak points.

And it’s great you’re reading this right now as you’d get all the expert info you sorely need. Make the most from the info you’ll get here, and you’ll surely join up hard stuff with so much ease.

But before we get to show what each welder can/can’t do, let’s take a quick look at each process;

MIG Process

Metal Inert Gas (MIG) or Gas Metal–Arc Welding (GMAW) is a process that welds two base metals with a shielding medium.

MIG Welding Process

In principle, MIG processes follow this pattern;

  • A welder g connected to a gas hose and wire feeder
  • Feeder wire passes through a welding gun onto base metals prepared and fitted with a clamp
  • Shielding gas protects the arc formed from an electrical current between the feeder wire and base metal

Flux Cored Process

Flux Cored Arc Welding (FCAW) is a much newer process than the MIG with a similar approach. The significant difference between flux-cored and a MIG welder is the shielding process. Gas tank supplies high argon or carbon gases with a MIG welder, but flux core shields are automatic.

The wire used in flux core welding comes with a metal surface and a flux-filled interior. This flux reacts to electrical current formed within the arc and melts, creating a shielding gas.

These welders function for industrial operations or where it’s challenging to use other processes.

Flux Cored and MIG Welder: Which is Better?

If you’ve got a Hobart flux core welder and a 240v MIG welder, you’ve got to find out which is stronger. To do so, you’ve got to consider several factors. These factors will be briefly discussed and tabulated below;


Getting good penetration is essential for a solid join, particularly in thicker metals. If you’re looking to weld much thicker metals, you’ve got to consider a flux cored ahead of MIG welders.

A flux-core welder allows its operator to pinpoint where to place welds, and its resulting arc sinks deeper than MIG processes. Welders keen on joining much thicker metals will likely opt for a flux core ahead of a MIG welder.

Thinner Metal Plates

Making use of a universal size welder for multiple processes is a mistake most newbie welders make. When it comes to welding metals thinner than 3/16 ” to 24 gauge metals, MIG welders are preferable. These welders will produce much neater welds with fewer spatters.

Since flux cored welders work with an open-air design, there’s a possibility of untidy welds on thin materials.

So, in the long run, MIG welders perform better than flux cored in welding lighter materials.

Gun Handling

When it comes to holding out your welding gun properly, you’ve got to pay full attention. If you’re not handling your gun right, issues could arise that’ll threaten the strength of your welds.

In this case, it’s the MIG welder that ranks higher.

MIG welders operate with a shielding process, which allows welders more flexibility in handling their thongs.

Flux-cored, on the other hand, has to be handled correctly to ensure a stable weld. Even if flux-cored welding is better for overhead welding, it has to get expertly handled. Moving a flux gun at inconsistent angles will lead to bad welds that may make a repeat necessary.

Welder Settings

Setting up your welder right determines to a great extent if your welds will be sturdy or not. When it comes to setting welders, a MIG process naturally has the upper hand. MIG welders are easy to operate, that’s why lots of newbie welders start with a MIG or stick welder first.

But when it comes to flux-cored welders, getting the right setting isn’t that straightforward. Most flux cored welders come with several knobs for getting a perfect weld. Any tiny shift to these knobs’ settings will likely interfere with your weld’s consistency.


Are you looking to weld in a windy condition? Without the right welding process, your joins may not be satisfactory and fall apart just like that.

Since MIG welders primarily operating with a shielding medium to create an arc, it is less preferred outdoors. Most welders that work in challenging conditions will opt for a flux cored welder outdoors. This mode limits MIG processes to indoor use or less windy conditions.

Ferrous and Non – Ferrous Metals

When it comes to welding ferrous metals, a MIG welder will perform much better than a flux core welder. Since MIG welders work with a solid wire electrode, its weld pool melts better onto ferrous base metals.

On the flip side, flux core welders are ideal for getting neater welds on non-ferrous metals with fewer weak spots.

Head-to-Head Comparison Table

Factor Flux Cored (FCAW) MIG (GMAW)
Penetration Stronger  
Thinner Metal Plates   Stronger
Gun Handling   Stronger
Welder Settings   Stronger
Location Stronger (Outdoors and Windy Conditions)  
Ferrous and Non – Ferrous Metals Stronger for Non-Ferrous Metals Stronger for Ferrous Metals

Final Word

After comparison of flux cored vs MIG strength, it’s evident from the six factors considered that a MIG welder performs better.

But when it comes to handling much thicker plates, flux-cored welders perform better at lower amperage. So before lighting up your welder, check out which process is ideal for you.