Mig Welding Wire Size Chart

Unlike welding with a stick welder mig welding is a semi automatic process.

Mig welding wire size chart.

Wire speed reference. The welding itself requires very little skill providing the mig welder settings are correct for the application. When welding with flux core wire the parameters can be entirely different. Multi pass welding or a beveled joint design may be required for material thickness 3 16 and greater depending on power output capability.

The 0 8mm figures have been extrapolated from the 0 6mm results so will be less reliable but they are at least a starting point. The 0 6mm wire size figures have been tested to 2mm and the figures are extrapolated. Other charts are available from cable manufacturers and welding reference books. Check with your machine manufacturer for any information that may pertain to your welding system.

As a guideline each 001 inch of material thickness requires 1 amp of output. Material thickness 024 030 035 045 030 035 045 24 gauge 025. Er5356 is a stiffer wire easier to feed and is used when more rigid higher strength weld properties are needed. The most common wire type is er4043 for all purpose work.

Only use a push gun technique when welding aluminum. When good results are achieved record the parameters. Er70s 6 is also better for creating a smooth transition from the weld to the base metal also known as wash in or tie in. Material thickness determines amperage.

Joint design position and other factors affect results and settings. The most common sizes most welders use are 023 030 035 045. The following basic guidelines are for mig welding steel with solid wire. Figure 5 is an example of a chart for selecting the proper welding cable size.

125 inch 125 amps. A quality mig wire is critical in robotic welding applications. If you are having feeding problems one thing you can try is a contact tip that is one size bigger than your wire. Better wash in may be a requirement in applications subject to fatigue.

As an example let s assume you have a 400 amp power source at 60 duty cycle and need a total combined length of electrode plus work cables of 100 feet. Most widely used mig welding electrode sizes. Er70s 6 wire can provide better wetting at the weld toe when compared to an er70s 3 wire. Some are much thicker for heavy industrial applications.

The information in this article pertain to welding with solid wire.