6 Best Miller Welders For Any Job and Process (Spring 2022)

We picked the highest-rated welding machines offered by Miller, from multi-process to those intended for specific welding task.
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Last updatedLast updated: March 28, 2022
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Miller Electric is a reliable brand when it comes to welding machines and all kinds of welding accessories. But what makes them worth buying, and how do they stand out from competition?

Miller welding machines have a powerful input and output power capacity, high duty cycle, three years of warranty, and are capable of welding using different processes. They are available in two versions, alternating current and direct current. Also, a wide variety of electrodes can be used, of all ranges and varieties. All these make a Miller Welder highly valuable and sought after.

Therefore, in this review, we’ll introduce you to the 6 best Miller welders for making the perfect welds and also tell you things to watch out for when you’re looking to bring one into your workshop. Let’s begin!

Top 6 Miller Welders Review 2022

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9.9
Features
  • Process: MIG, DC TIG, Stick
  • Input voltage: 120/240V
  • Output amps: 20–230A
  • Duty cycle: 20% (TIG, Stick), 40% MIG
  • Material thickness: up to 3/8” mild steel
  • Dimensions: 20.5″ x 11.25″ x 12.5″
  • Weight: 38 lbs

Our Editor’s Choice and overall Best Miller Welder is the Miller Mutimatic 215 Multiprocess Welder. We have selected this because it is ideal for working with three welding processes simultaneously: MIG, DC TIG, and stick welding. It is a piece of equipment that has a color LCD screen, which allows the equipment to be handled and adjusted easily. Also, if in any case, you exceed the duty cycle, you don’t need to worry; it will automatically turn off.

You don’t have to be a trained welder to use this multiprocess machine. The welder is ideal for DIYers and beginners. It’s a good choice for FCAW and GMAW applications. It comes with various accessories including a ground cable, gun, torch straps, and electrode holder. It is a light equipment of approximately 38 pounds and in case you need to move it, it comes with handles. During the welding work, you can change the wires. As for its power, it is capable of reaching up to 240 V, the best of all is that you can carry out three processes in a single device.

It should also be mentioned that the Miller Multimatic 215 is equipped with a digital display, which makes it easy to take measurements. The screen is simple to use and comes with great features, including an installation guide. In addition, the product has two gas inlets, allowing you to easily switch between processes. So you don’t need to disconnect any gas tank, saving you time and energy.

What makes it stand out?

  • The accessories that come with the equipment such as cables are of high quality
  • The LCD screen is clear and comes with a protector
  • The machine is sold at a good price
  • Arc is very stable
  • The machine's portability is outstanding; it can be carried with you up a ladder

Which disadvantages must you keep in mind?

  • The MIG gun could be sturdier
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Consumer Engagement
Chosen by 5186 people in the past 30 days
9.8
Customer Feedback
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9.6
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Features
  • Process: AC/DC TIG, MIG, flux-cored, and stick
  • Input voltage: 120/240V
  • Output amps: 20–230A
  • Duty cycle: 15% (Stick), 20% (TIG), 40% (MIG)
  • Material thickness: up to 3/8″ (MIG and Stick) or 1/4″ (TIG)
  • Dimensions: 21.5″ x 11.25″ x 17.15″
  • Weight: 56 lbs

Our Best Upgrade Pick is the Miller Multimatic 220 Multiprocess Welder, a machine that has been tested and trusted for light industrial applications. It is designed for longevity, which is evident from the construction. Although it doesn’t come with many extra accessories and features, this machine is durable and easy to use.

It’s a more powerful version of the Miller 215 model. Although both are multiprocess welders, the 220 Multimatic can run MIG processes (GMAW), flux-cored (FCAW), AC / DC TIG (GTAW), pulsed TIG pulsed (GTAW-P), and DC stick (SMAW). The machine is ideal for light manufacturing, maintenance and repair works, auto body construction, and use in the farm and home.

Perfect for hobbyists and small shops, the Multimatic 220 AC/DC gives you the freedom to weld any process. It is a portable, powerful, and easy-to-use machine. Setup and switching processes are quick and easy while ensuring excellent arc quality on 120 or 240-volt power. That said, be warned that while the welder is a real pleasure during use, it does come with a pretty hefty price tag.

What makes it stand out?

  • Dual voltage welding machine; you can switch between 120 and 240 volts
  • A multiprocess welder that can run up to four welding processes
  • Ideal for hobbyists and beginners
  • Setting up is easy

Which disadvantages must you keep in mind?

  • The pricing could be reduced; it's almost 100% more expensive than its predecessor, the Multimatic 215
  • Quite heavier than the 215
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Chosen by 6715 people in the past 30 days
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9.1
Features & Benefits
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9.2
9.5
Features
  • Process: Stick
  • Input voltage: 120/240V
  • Output amps: 20–160A
  • Duty cycle: 30%
  • Material thickness: up to 3/8″ mild steel
  • Dimensions: 7.125″ x 10.5″ x 13.375″
  • Weight: 15 lbs

There are a couple of reasons why the Miller Thunderbolt 160 DC is our best stick welder. The machine is a dual voltage welder that can run on a connection of 120 or 240 volts. When connected to 120V, the duty cycle at 65 amps is 20 percent and when connected to 240V, the duty cycle at 160 amps is 30 percent. Also, at 15 lbs rated weight, it is one of the lightest welding machines in the review.

It’s a reliable, portable, and powerful stick welder that weighs more than 40 pounds less than the Miller 220 Multimatic. It’s versatile, with 120V and 240V power capability. The Hot Start™ Technology easy, fast and reliable arc starts. Precise Amperage Control provides exact and infinite control of amperage and heat output. The Multi-Voltage Plug (MVP) connects to 120 or 240-volt outlets without tools. You can choose the plug that fits the receptacle and connect it to the power cord easily.

The Thunderbolt Stick Welder is suitable for those interested in DIY, farm and ranch maintenance and repair, field ops, and shipbuilding. Weldable metals include steel and stainless steel.

What makes it stand out?

  • It is dual voltage with a Multi-Voltage Plug (MVP™)
  • Can be connected to 120 or 240 V outlets without tools
  • Hot Start™ technology allows easy, fast, and reliable arc starting
  • Precise and accurate unlimited heat output and amperage control
  • It's a low budget welding machine

Which disadvantages must you keep in mind?

  • It cannot run any other welding process aside stick
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Consumer Engagement
Chosen by 3529 people in the past 30 days
9.3
Customer Feedback
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9.0
Features & Benefits
Product Review
8.9
9.3
Features
  • Process: TIG, Stick
  • Input voltage: 120/240V
  • Output amps: 5–160A
  • Duty cycle: 60%
  • Material thickness: 02″ to 3/16″
  • Dimensions: 5.6″ x 10.3″ x 13.5″
  • Weight: 13 lbs

The Maxstar 161 is our favorite TIG welder as it is ideal for welding with great performance. Lightweight and portable, you won’t find any model that is as easily transportable. It is a dual voltage piece of equipment that has 120/240 V input power. The Miller brand welder has a compact design that makes it more practical in relation to other welding equipment. Regardless, it has inverter technology that allows it to save energy.

One of the main features of the Maxstar 161 is that a torch is not required due to the gas solenoid. On the other hand, this machine has one of the advanced technologies found in premium welding machines – the Hot Start, which is ideal for preventing the part from adhering to the electrode. So, you can say goodbye to sticky welds!

Like other Miller machines, it comes with some essential accessories such as cables, electrodes, among others. If you need a welder with good performance and that guarantees good results, you should give this a try.

What do we love it for?

  • Its compact design; it is one of the most comfortable and easy to handle welders
  • It's still more expensive than the previous model but the price is fair
  • It is a quality piece of equipment

What were we disappointed with?

  • Could be designed with novice welders in mind
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Consumer Engagement
Chosen by 3643 people in the past 30 days
9.1
Customer Feedback
Customer Feedback
8.8
Brand Reputation
Based onweb analytics
8.9
Features & Benefits
Product Review
8.7
9.1
Features
  • Process: MIG, Flux-cored
  • Input voltage: 208/240V; 230/460/575V
  • Output amps: 30–300A
  • Duty cycle: up to 60%
  • Material thickness: 22 gauge to 1/2″ mild steel
  • Dimensions: 30″ x 19″ x 40″
  • Weight: 205 lbs

The MILLER MILLERMATIC 252 is the best option for those looking for an MIG welder. The MIG process welder produces the highest output in its class and provides the longest lasting weld in high end applications. The welder has an infinite voltage control system with self-calibrating digital meters. This allows voltage and wire feed speed to be easily preset and guarantees precise welding parameters and precision.

It comes with integrated digital timers and presettable timers for preflow/postflow, burnback, and (stitch) spot and delay. There are separate timers for MIG and spool guns. Also, line voltage compensation keeps power constant even if input power varies ±10%. The machine has an Active Arc Stabilizer™ that minimizes weld cleanup and has been shown to provide excellent starts that are superior to the competition.

It also features the Auto Gun Detect™ technology that allows the operator to simply trigger the MIG gun, spool gun, and push-pull gun. The Fan-On-Demand™ power supply cooling system runs only when needed. This reduces noise, energy consumption, and the amount of contaminants entering the machine. Also provided are a flow meter regulator and gas hose for argon or AR/CO2 mix.

What makes it stand out?

  • Comes complete with a MIG gun, work lead, and clamp
  • Automatically detects and retrieves active torch voltage, wire feed speed, and timer
  • Heavy-duty aluminum system with two feed rollers
  • Includes a 10 ft industrial power cord

Which disadvantages must you keep in mind?

  • It is a heavy welder; weighs 205 pounds, more than 10x of average welders
  • It's pricey but worth it
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Consumer Engagement
Chosen by 2383 people in the past 30 days
8.8
Customer Feedback
Customer Feedback
8.5
Brand Reputation
Based onweb analytics
8.3
Features & Benefits
Product Review
8.3
8.8
6
Best for Light Industrial Applications

Miller Millermatic 211 MIG Welder

Features
  • Process: MIG, Flux-cored
  • Input voltage: 120/240V
  • Output amps: 30–230A
  • Duty cycle: up to 40%
  • Material thickness: 24 gauge to 3/8″
  • Dimensions: 12.5″ x 11.25″ x 20.5″
  • Weight: 38 lbs

The Miller Millermatic 211 is another MIG welder but, this time, this is a more portable and lighter welding machine that would be suitable for light industrial applications. It is ideal for welding aluminum, stainless and mild steel. The Millermatic 211 has advanced automatic adjustment and also comes with protection for detecting overheating, simply emitting a light signal to turn off the equipment. It is a piece of equipment that helps to save energy and it is not very noisy due to its cooling system. The input power is between 120 V and 140 V.

Likewise, it includes some accessories such as power cables with plug, thickness gauge, cable, gun, among others. Another aspect to mention is that you can make various combinations of cable and gas. What you only need to do is indicate the thickness and diameter to be used in its Advanced Auto-Set function.

The Millermatic 211 from Miller Electric is designed for commercial use and allows you to run it on 120 or 240 volts for added flexibility. It offers a 40% duty cycle at 150 amps, and it works with heavy-duty or cored cables.

Plus, it’s backed by a 3-year warranty that includes adapters for 120 and 240-volt outlets. Thus, this is a good model if you are interested in finding the best professional or industrial MIG welder for light use.

What makes it stand out?

  • The welder operates on 120 or 240 volts
  • You won't have to worry about a splashing start
  • Impressive duty cycle of 40% at 150 amps
  • Inverter technology

Which disadvantages must you keep in mind?

  • Considering it's a MIG-only welder, we expect the machine to be less pricey
  • Accessories do not include a face mask

Things to Consider

Miller welding machines are devices used for the alloying of metals together. It can be iron, stainless steel, or aluminum. The weld produced is a combination of the two joined materials. Whether you are a do-it-yourselfer, a welding hobbyist, a beginner, or a welding professional, you’d find a Miller Welder that’s ideal for you. With Miller Electric welders, you’d find welding machines that run the MIG, TIG, stick, flux-cored, or multiple processes. In this review, we’ll provide more information on choosing Miller branded welders.

Why Pick Miller Electric Welders?

Miller Electric is one of the largest manufacturers of welding and cutting equipment in the world and provides its customers with equipment of extraordinary reliability under all conditions of use. It manufactures the highest quality welding machines available on the market. Miller Electric welders are made in the USA. So, the reliability of the machines is guaranteed.

There are Miller welders for every budget. You can find models as low as $700 up to premium models of around $4,000 to $5,000.

Features to Consider Before You Buy a Welder

Below are some of the features needed to consider before buying a welding machine.

Type and Processes

6 Best Miller Welders For Any Job and Process (Spring 2022)

Miller offers plenty of models, from one- to multiprocess ones

Before embarking on any purchase, you must inform yourself about the different types of welding machines that exist. First, know that there are 4 of them, including the MMA model, the MIG MAG model, the TIG model, and the multiprocess welders.

The MMA welding station is equipped with electrodes and can weld metal with a thickness of approximately 0.08 to 0.4 inches. A potentiometer also allows you to adjust the welding power adapted to the thickness of the metal to be welded. Sold at an affordable price, it is lightweight and has great ease of use for the benefit of beginners.

As for the MIG MAG welder, it has a fine wire for close spot assembly and a solid wire with gas which makes it effective for intensive welding. Reserved for professionals, this type of welding machine is very versatile. Then, for the semi-automatic model, a cored wire allows it to increase the welding output without removing the slag.

Finally, the TIG model can weld all types of metals and offers remarkable welding precision, with a smoother finish.

Voltage

When choosing a welding machine, you need to know what input voltage you need. You have up to three key options in this area. The first is a 120V input, which is your normal household power supply. Then, the second is a 240V input. Meanwhile, the third is the dual voltage 120V/240V input. Most Miller welders have this capability, from the Miller Multimatic 215 to the Miller Multimatic 220, Miller Maxstar 161, and the Miller Millermatic 211.

If you’re just welding in your home shop, a 120V TIG welder should be enough for you. In contrast, the 120/240V input offers maximum flexibility, allowing more power. However, you don’t need a 240V input if you are running the machine from your household power supply.

Output Amps

The output power of an electrode station varies from one model to another and generally determines its ability to work on metals of different natures and electrodes of different sizes.

High power will therefore always be more interesting, but it should not be forgotten either that on this type of device, high power goes with a high price. This brings you back to the main criterion which is to define above all the application you will make of your welding station.

If it is to work on thin metals, there is no need to use large diameter electrodes and therefore a powerful welding machine. A single-phase model of 200 A maximum may very well suit you for occasional or even regular use since it allows you to work on a thickness of between 2 and 20 mm approximately.

On the other hand, for heavy work in business and industry, a 400A to 600A three-phase semi-automatic welding station will be necessary to weld on a thickness of up to 40 mm.

Duty Cycle

6 Best Miller Welders For Any Job and Process (Spring 2022)

The duty cycle, which is always given in specs, indicates the percentage of time the welder will be able to operate safely at a given amperage

A duty cycle of around 20 percent is enough for welding enthusiasts and beginners in general. A duty cycle of 40 to 60 percent is often enough for TIG welders in construction and industry. Meanwhile, professional welders in construction industries need a 100 percent duty cycle because of the long welding time that could be lost waiting for the welding machine to cool down. In terms of duty cycle, the Miller Millermatic 252 is the highest performing, as it has a duty cycle of 60 percent at 30 to 300 amps output.

Wire Size

The electrodes are available in different diameters, which determine the thickness of the parts to be welded and the required intensity. As a guide, the smallest electrode size (Ø 1.60 mm) makes it possible to weld parts approximately 2 mm thick with an intensity of 50 A.

As a general rule, the diameter of the electrode should be less than or equal to the thickness to be welded. In direct current, the negative polarity must be applied to the rutile coated electrode. Always keep your coated electrodes in a dry place away from humidity and shocks.

Electrode Type

Below, we consider the most common types of electrodes.

Stick Electrodes

Regarding MMA coated electrodes, there are three categories of stick welding electrodes:

  • Rutile electrodes: These have titanium oxide, ferrous alloy, and silicate coating. These are the most commonly used coated electrodes.
  • Basic electrodes: These electrodes are coated in calcium carbonate and alloy, allowing the melting temperature to be lowered.
  • Cellulosic electrodes: These have coatings of cellulose and organic materials to ensure an abundance of gas and optimize penetration.

Good to know: on an MMA welding machine, it is the chosen electrode that determines the choice of polarity. With the so-called rutile electrode, the polarity is direct: electrode at -, ground at +. For a basic electrode, the polarity is reversed: electrode at + and ground at -.

Tungsten Electrodes for TIG Welding

There are many categories of Tungsten electrodes. The choice of one or the other is conditioned both by the welding to be done and the welding current. Color codes make it easy to differentiate and identify the type of electrode. WP pure Tungsten electrodes, Tungsten + Zircon WZ electrodes, Tungsten Lanthanum WL10/WL15/WL20 electrodes, WC 20 Cerium Tungsten electrodes, and Tungsten + rare earth E3 or WR2 electrodes. Note that there are also Thoriated Tungsten WT electrodes which are usable for welding steel and stainless steel.

MIG-MAG Welding Wires

In the MIG welding process, it is one steel welding wire, fed continuously via a wire feeder, which acts both as a fusible electrode and as filler metal. The wires are also distinguished by their design. The bare or solid wire requires the supply of gas for its fusion; the cored wire allows welding without gas even outdoors, thanks to a flux protecting the weld pool, consisting of rutile or basic powder. These MIG – MAG wires are available in reels. The coils are generally sized to match the capacities of the reels of the welding machines.

Size and Weight

6 Best Miller Welders For Any Job and Process (Spring 2022)

If portability matters to you, check the size and weight of a welder you intend to buy

If you need to move it to your construction site or field, you need a portable machine like the Miller Maxstar 161 STH TIG welder. Meanwhile, you have to know that large-sized welders offer more in terms of performance and welding possibilities. For example, multiprocess welders are often larger in dimensions and heavier. Even in this case, portability is still a criterion to watch out for. Ensure such a machine has a pushcart and wheels, as the Miller Millermatic 252 comes with, for portability.

Accessories

You must consider the number of accessories that come with your welder. Indeed, some models are supplied with short or long cables for powering the welding machine and a welding mask to protect the user during his work. Unfortunately, there are also cheaper welder models that do not come with these accessories. Other models such as some MMA Inverters are not supplied with electrodes which must be purchased separately.

Warranty

Although high-quality power tools such as Miller’s are not likely to develop issues during the first years of use. However, you have to understand that these machines can be quite expensive. So, it is always good to get a device that has a manufacturer’s warranty.

Miller goes further as far as warranty coverage is concerned. Most of the time, they offer a warranty of three years, which shows the confidence they have in the machines.

Price

Sorry to disappoint those looking for budget welders, you won’t find that with Miller Electric. You’ll find welding machines that are sold for $70 to $300 by other cheaper brands on the market. But the cheapest models from Miller Electric are usually around $700 to $1000. There are high-quality multiprocess welders from Miller Electric that cost up to $4,500. But you will not end up regretting that you invested that much in a welder. This is a conclusion we reached after analyzing the experience of hundreds of Miller welder users.

FAQ

Because they’re premium quality welding machines, most Miller Electric welders come with three years warranty, which shows how much the brand trusts the durability of its products.

For occasional welding tasks, a metal inert gas (MIG) welder is often the most recommended. Our best option for occasional light applications is the Miller Millermatic 211 MIG welder. MIG welders are the most ideal type of welders for DIYers, hobbyists, and beginners who want light-duty machines that are easy to use and don’t come with a roof-hitting cost.

Despite their ease of use, metal inert gas (MIG) welders are the best type of welders for professional and industrial use. They can be used in the automobile manufacturing and shipbuilding industries.

Our Verdict

Miller branded welders are good welding machines if you’re looking for the best quality welders on the market with the highest guarantee. The brand has produced dozens of models, but we’ve tried to narrow them down to only the 6 best Miller welder models.

Out of these, the Miller Multimatic 215 is our favorite and the Editor’s Choice. The multiprocess welder is ideal for working with three welding processes simultaneously: MIG, DC TIG, and stick welding. The welder is ideal for DIYers and beginners and is a good choice for FCAW and GMAW applications

Our Upgrade Pick and the runner-up is the Miller Multimatic 220 welder. This is a more powerful version of the Miller 215 model. However, the 220 Multimatic can run MIG, flux-cored, AC / DC TIG, pulsed TIG, and DC stick welding processes.

Finally, the Miller Thunderbolt 160DC is the best stick welder for MMA fans. It’s a reliable, portable, and powerful stick welder that weighs more than 40 pounds less than the Miller 220 Multimatic. It’s versatile, with 120V and 240V dual voltage capability.

References

1.
Our Company | MillerWelds
Learn what makes Miller Electric Mfg. Co., located in Appleton, WI, the leading brand in advanced, solution-focused welding products.
2.
What You Need To Know About Welding Electrodes - Tulsa Welding School
If you are interested in a welding career, you might have already looked into the welding tools and equipment that are used.
3.
The different types of electrodes used in orbital TIG welding
Tungsten electrodes are classified according to their chemical composition. Here are the types of electrodes used in orbital TIG welding.
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