Mig Welding Wire Size Chart

The welding itself requires very little skill providing the mig welder settings are correct for the application.

Mig welding wire size chart.

The information in this article pertain to welding with solid wire. Figure 5 is an example of a chart for selecting the proper welding cable size. The most common wire type is er4043 for all purpose work. A quality mig wire is critical in robotic welding applications.

The most common sizes most welders use are 023 030 035 045. Only use a push gun technique when welding aluminum. If you are having feeding problems one thing you can try is a contact tip that is one size bigger than your wire. 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.

Unlike welding with a stick welder mig welding is a semi automatic process. The following basic guidelines are for mig welding steel with solid wire. The 0 6mm wire size figures have been tested to 2mm and the figures are extrapolated. Some are much thicker for heavy industrial applications.

When welding with flux core wire the parameters can be entirely different. 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. Check with your machine manufacturer for any information that may pertain to your welding system. When good results are achieved record the parameters.

Wire speed reference. Other charts are available from cable manufacturers and welding reference books. 125 inch 125 amps. 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. Material thickness determines amperage. Browse suggested weld parameter settings for stick welding tig welding mig solid wire welding and mig flux core welding. Er70s 6 wire can provide better wetting at the weld toe when compared to an er70s 3 wire.

Er5356 is a stiffer wire easier to feed and is used when more rigid higher strength weld properties are needed. Multi pass welding or a beveled joint design may be required for material thickness 3 16 and greater depending on power output capability. Double click on chart to view quick guide for selecting mig wire size and welder amperage for your application. Better wash in may be a requirement in applications subject to fatigue.

Typical mig welding electrodes are a solid wire ranging from a thickness of 023 to 045.