Mig Welding Wire Size Chart

Double click on chart to view quick guide for selecting mig wire size and welder amperage for your application.

Mig welding wire size chart.

Figure 5 is an example of a chart for selecting the proper welding cable size. Unlike welding with a stick welder mig welding is a semi automatic process. Typical mig welding electrodes are a solid wire ranging from a thickness of 023 to 045. A quality mig wire is critical in robotic welding applications.

When good results are achieved record the parameters. 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. If you are having feeding problems one thing you can try is a contact tip that is one size bigger than your wire. The most common wire type is er4043 for all purpose work.

The 0 6mm wire size figures have been tested to 2mm and the figures are extrapolated. 125 inch 125 amps. Most widely used mig welding electrode sizes. Only use a push gun technique when welding aluminum.

Better wash in may be a requirement in applications subject to fatigue. Check with your machine manufacturer for any information that may pertain to your welding system. The information in this article pertain to welding with solid wire. 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.

Other charts are available from cable manufacturers and welding reference books. Multi pass welding or a beveled joint design may be required for material thickness 3 16 and greater depending on power output capability. Er70s 6 wire can provide better wetting at the weld toe when compared to an er70s 3 wire. The most common sizes most welders use are 023 030 035 045.

Browse suggested weld parameter settings for stick welding tig welding mig solid wire welding and mig flux core welding. Er5356 is a stiffer wire easier to feed and is used when more rigid higher strength weld properties are needed. As a guideline each 001 inch of material thickness requires 1 amp of output. When welding with flux core wire the parameters can be entirely different.

The welding itself requires very little skill providing the mig welder settings are correct for the application. Wire speed reference. Material thickness determines amperage. Joint design position and other factors affect results and settings.

Material thickness 024 030 035 045 030 035 045 24 gauge 025.