All suggested settings are approximate. Welds should be tested to comply to your specifications.

Aluminum

For aluminum, the most common wire type is ER4043 for all-purpose work. ER5356 is a stiffer wire (easier to feed), and is used when more rigid, higher-strength weld properties are needed. The best feeding of wire for aluminum is done with a spool gun. If you can't use a spool gun, use the shortest gun possible and keep the gun as straight as possible. Use Argon only for shielding gas.

Choose your material thickness:

1/8" (3.2mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
Not Recommended

Shielding Gas & Voltage Range**:
Not Recommended

Amperage Range:
Not Recommended

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
.035" (0.9 mm) at 350-400 ipm
3/64" (1.2 mm) at 240-270 ipm

Shielding Gas & Voltage Range**:
Argon (AL): 21-22 Volts

Amperage Range:
110-130

3/16" (4.8mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
Not Recommended

Shielding Gas & Voltage Range**:
Not Recommended

Amperage Range:
Not Recommended

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
.035" (0.9 mm) at 425-450 ipm
3/64" (1.2 mm) at 300-325 ipm

Shielding Gas & Voltage Range**:
Argon (AL): 23-24 Volts

Amperage Range:
140-150

1/4" (6.4mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
Not Recommended

Shielding Gas & Voltage Range**:
Not Recommended

Amperage Range:
Not Recommended

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
3/64" (1.2 mm) at 350-375 ipm
1/16" (1.6 mm) at 170-185 ipm

Shielding Gas & Voltage Range**:
Argon (AL): 24-25 Volts

Amperage Range:
180-210

5/16" (7.9mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
Not Recommended

Shielding Gas & Voltage Range**:
Not Recommended

Amperage Range:
Not Recommended

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
3/64" (1.2 mm) at 400-425 ipm
1/16" (1.6 mm) at 200-210 ipm

Shielding Gas & Voltage Range**:
Argon (AL): 26-27 Volts

Amperage Range:
200-230

7/16" (11.1mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
Not Recommended

Shielding Gas & Voltage Range**:
Not Recommended

Amperage Range:
Not Recommended

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
1/16" (1.6 mm) at 240-270 ipm

Shielding Gas & Voltage Range**:
Argon (AL): 28-29 Volts

Amperage Range:
280

1/2" (12.7mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
Not Recommended

Shielding Gas & Voltage Range**:
Not Recommended

Amperage Range:
Not Recommended

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
1/16" (1.6 mm) at 290-300 ipm

Shielding Gas & Voltage Range**:
Argon (AL): 29-30 Volts

Amperage Range:
300

Stainless Steel

Welding stainless steel may not be as difficult as welding aluminum, but the metal does have specific properties that make it different than welding on common steels. Use a triple-mix gas (Helium/Argon/CO2) or spray shielding gas for stainless steels.

Choose your material thickness:

18 ga. (1.2mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
.035" (0.9 mm) at 120-150 ipm

Shielding Gas & Voltage Range**:
Helium+Argon+CO2: 19-20 Volts

Amperage Range:
50-60

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
Not Recommended

Shielding Gas & Voltage Range**:
Not Recommended

Amperage Range:
Not Recommended

16 ga. (1.6mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
.035" (0.9 mm) at 180-205 ipm

Shielding Gas & Voltage Range**:
Helium+Argon+CO2: 19-20 Volts

Amperage Range:
70-80

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
.035" (0.9 mm) at 425-450 ipm
3/64" (1.2 mm) at 300-325 ipm

Shielding Gas & Voltage Range**:
Argon (AL): 23-24 Volts

Amperage Range:
140-150

14 ga. (2mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
.035" (0.9 mm) at 230-275 ipm

Shielding Gas & Voltage Range**:
Helium+Argon+CO2: 20-21 Volts

Amperage Range:
90-110

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
Not Recommended

Shielding Gas & Voltage Range**:
Not Recommended

Amperage Range:
Not Recommended

12 ga. (2.6mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
.035" (0.9 mm) at 300-325 ipm

Shielding Gas & Voltage Range**:
Helium+Argon+CO2: 20-21 Volts

Amperage Range:
120-130

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
Not Recommended

Shielding Gas & Voltage Range**:
Not Recommended

Amperage Range:
Not Recommended

3/16" (4.8mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
.035" (0.9 mm) at 350-375 ipm

Shielding Gas & Voltage Range**:
Helium+Argon+CO2: 20-21 Volts

Amperage Range:
140-150

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
.035" (0.9 mm) at 400-425 ipm

Shielding Gas & Voltage Range**:
98% Argon/2% O2: 23-24 Volts

Amperage Range:
160-170

1/4" (6.4mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
.035" (0.9 mm) at 400-425 ipm

Shielding Gas & Voltage Range**:
Helium+Argon+CO2: 20-21 Volts

Amperage Range:
160-170

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
.035" (0.9 mm) at 450-475 ipm

Shielding Gas & Voltage Range**:
98% Argon/2% O2: 24-25 Volts

Amperage Range:
180-190

5/16" (7.9mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
.035" (0.9 mm) at 450-475 ipm

Shielding Gas & Voltage Range**:
Helium+Argon+CO2: 21-22 Volts

Amperage Range:
180-190

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
.045" (1.1 mm) at 250-300 ipm

Shielding Gas & Voltage Range**:
98% Argon/2% O2: 24-25 Volts

Amperage Range:
200-210

3/8" (9.5mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
Not Recommended

Shielding Gas & Voltage Range**:
Not Recommended

Amperage Range:
Not Recommended

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
1/16" (1.6 mm) at 140-170 ipm

Shielding Gas & Voltage Range**:
98% Argon/2% O2: 25-26 Volts

Amperage Range:
250-275

7/16" (11.1mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
Not Recommended

Shielding Gas & Voltage Range**:
Not Recommended

Amperage Range:
Not Recommended

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
1/16" (1.6 mm) at 170-200 ipm

Shielding Gas & Voltage Range**:
98% Argon/2% O2: 26-27 Volts

Amperage Range:
275-300

1/2" & Up (12.7mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
Not Recommended

Shielding Gas & Voltage Range**:
Not Recommended

Amperage Range:
Not Recommended

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
1/16" (1.6 mm) at 200-230 ipm

Shielding Gas & Voltage Range**:
98% Argon/2% O2: 27-32 Volts

Amperage Range:
300-325

Steel (with Solid Core Wire)

For steel, there are two common wire types. Use an AWS classification ER70S-3 for all purpose, economical welding. Use ER70S-6 wire when more deoxidizers are needed for welding on dirty or rusty steel.

  • Must be used with CO2 or 75% Argon/25% (C-25) shielding gas
  • Indoor use with no wind
  • For auto body, manufacturing, fabrication
  • Welds thinner materials (22 gauge) than flux cored wires

Choose your material thickness:

22 ga. (0.8mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
.030" (0.8 mm) at 90-100 ipm

Shielding Gas & Voltage Range**:
CO2: 16-17 Volts, 75% Argon/25% CO2: 15-16 Volts
CO2 gas is economical and has deeper penetration on steel, but may be too hot for thin metal. 75% Argon / 25% CO2 is better on thin steels, has less spatter and better bead appearance.

Amperage Range:
40-55

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
Not Recommended

Shielding Gas & Voltage Range**:
Not Recommended

Amperage Range:
Not Recommended

20 ga. (0.9mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
.030" (0.8 mm) at 120-135 ipm
.035" (0.9 mm) at 105-115 ipm

Shielding Gas & Voltage Range**:
CO2: 17-18 Volts, 75% Argon/25% CO2: 15-16 Volts
CO2 gas is economical and has deeper penetration on steel, but may be too hot for thin metal. 75% Argon / 25% CO2 is better on thin steels, has less spatter and better bead appearance.

Amperage Range:
50-60

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
Not Recommended

Shielding Gas & Voltage Range**:
Not Recommended

Amperage Range:
Not Recommended

18 ga. (1.2mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
.030" (0.8 mm) at 150-175 ipm
.035" (0.9 mm) at 140-160 ipm
.045" (1.1 mm) at 70 ipm

Shielding Gas & Voltage Range**:
CO2: 17-18 Volts, 75% Argon/25% CO2: 15-16 Volts
CO2 gas is economical and has deeper penetration on steel, but may be too hot for thin metal. 75% Argon / 25% CO2 is better on thin steels, has less spatter and better bead appearance.

Amperage Range:
70-80

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
Not Recommended

Shielding Gas & Voltage Range**:
Not Recommended

Amperage Range:
Not Recommended

16 ga. (1.6mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
.030" (0.8 mm) at 220-250 ipm
.035" (0.9 mm) at 180-220 ipm
.045" (1.1 mm) at 90-110 ipm

Shielding Gas & Voltage Range**:
CO2: 17-18 Volts, 75% Argon/25% CO2: 17-18 Volts
CO2 gas is economical and has deeper penetration on steel, but may be too hot for thin metal. 75% Argon / 25% CO2 is better on thin steels, has less spatter and better bead appearance.

Amperage Range:
90-110

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
Not Recommended

Shielding Gas & Voltage Range**:
Not Recommended

Amperage Range:
Not Recommended

14 ga. (2.0mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
.030" (0.8 mm) at 250-340 ipm
.035" (0.9 mm) at 240-260 ipm
.045" (1.1 mm) at 120-130 ipm

Shielding Gas & Voltage Range**:
CO2: 17-18 Volts, 75% Argon/25% CO2: 17-18 Volts
CO2 gas is economical and has deeper penetration on steel, but may be too hot for thin metal. 75% Argon / 25% CO2 is better on thin steels, has less spatter and better bead appearance.

Amperage Range:
120-130

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
Not Recommended

Shielding Gas & Voltage Range**:
Not Recommended

Amperage Range:
Not Recommended

Steel (with Flux Core Wire)

Choose your material thickness:

3/32" (2.4mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
.045" (1.1 mm) at 175-185 ipm

Shielding Gas & Voltage Range**:
CO2: 19-21 Volts, 75% Argon/25% CO2: 18-20 Volts
CO2

Amperage Range:
110-125

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
.035" (0.9 mm) at 145-155 ipm
.045" (1.1 mm) at 75-85 ipm

Shielding Gas & Voltage Range**:
14-15 Volts

Amperage Range:
110-125

1/8" (3.2mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
.045" (1.1 mm) at 210-230 ipm

Shielding Gas & Voltage Range**:
CO2: 20-22 Volts, 75% Argon/25% CO2: 20-21 Volts
CO2

Amperage Range:
140-155

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
.035" (0.9 mm) at 175-185 ipm
.045" (1.1 mm) at 85-95 ipm

Shielding Gas & Voltage Range**:
14-15 Volts

Amperage Range:
140-155

3/16" (4.8mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
.045" (1.1 mm) at 235-255 ipm
1/16" (1.6 mm) at 180-200 ipm

Shielding Gas & Voltage Range**:
CO2: 21-23 Volts, 75% Argon/25% CO2: 21.5-22.5 Volts
CO2

Amperage Range:
.045" (1.1 mm) at 155-170 amps
1/16" (1.6 mm) at 190-220 amps

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
.035" (0.9 mm) at 205-215 ipm
.045" (1.1 mm) at 105-115 ipm

Shielding Gas & Voltage Range**:
15-16 Volts

Amperage Range:
190-220

1/4" (6.4mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
.045" (1.1 mm) at 255-280 ipm
1/16" (1.6 mm) at 300-325 ipm

Shielding Gas & Voltage Range**:
.045" (1.1 mm):
- CO2: 24-25 Volts
- 75% Argon/25% CO2: 23-24 Volts
1/16" (1.6 mm):
- CO2: 28-29 Volts
- 75% Argon/25% CO2: 26-28 Volts

Amperage Range:
.045" (1.1mm) at 140-155 amps
1/16" (1.6mm) at 260-280 amps

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
.035" (0.9 mm) at 220-230 ipm
.045" (1.1 mm) at 125-135 ipm

Shielding Gas & Voltage Range**:
.035" (0.9 mm) at 15-16 volts
.045" (1.1 mm) at 16-17 volts

Amperage Range:
170-190

3/8" (9.5mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
1/16" (1.6 mm) at 350-400 ipm
3/32" (2.4 mm) at 120-130 ipm

Shielding Gas & Voltage Range**:
1/16" (1.6 mm):
- CO2: 29-30 Volts
- 75% Argon/25% CO2: 27-28 Volts
3/32" (2.4 mm):
- CO2: 29-30 Volts
- 75% Argon/25% CO2: 28-29 Volts

Amperage Range:
1/16" (1.6 mm) at 330-375 amps
3/32" (2.4 mm) at 340-360 amps

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
.035" (0.9 mm) at 245-255 ipm
.045" (1.1 mm) at 165-175 ipm

Shielding Gas & Voltage Range**:
.035" (0.9 mm) at 16-17 Volts
.045" (1.1 mm) at 17-18 volts

Amperage Range:
330-375

1/2" (12.7mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
3/32" (2.4mm) at 180-210 ipm
1/8" (3.2mm) at 100-110 ipm

Shielding Gas & Voltage Range**:
3/32" (2.4mm):
- CO2: 30-31 Volts
- 75% Argon/25% CO2: 29-30 Volts
1/8" (3.2mm):
- CO2: 29-30 Volts
- 75% Argon/25% CO2: 29-30 Volts

Amperage Range:
3/32" (2.4mm) at 430-470 amps
1/8" (3.2mm) at 450-500 amps

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
Not Recommended

Shielding Gas & Voltage Range**:
Not Recommended

Amperage Range:
Not Recommended

5/8" (15.9mm) Click to expand

Short Circuit Transfer
(generally used for thinner metals and out of position welding)

Wire Size & Wire Feed Speed*:
3/32" (2.4mm) at 230-250 ipm
1/8" (3.2mm) at 140-160 ipm

Shielding Gas & Voltage Range**:
3/32" (2.4mm):
- CO2: 31-32 Volts
- 75% Argon/25% CO2: 30-31 Volts
1/8" (3.2mm):
- CO2: 29-30 Volts
- 75% Argon/25% CO2: 29-30 Volts

Amperage Range:
3/32" (2.4mm) at 490-525 amps
1/8" (3.2mm) at 550-600 amps

Spray Arc Transfer
(generally used for thicker metals in the flat or slightly horizontal position)

Wire Size & Wire Feed Speed*:
Not Recommended

Shielding Gas & Voltage Range**:
Not Recommended

Amperage Range:
Not Recommended

* Wire Feed Speed is a starting value only and can be fine-tuned while welding.
** CO2 gas is economical and has deeper penetration on steel, but may be too hot for thin metal. 75% Argon / 25% CO2 is better on thin steels, produces less spatter and better bead appearance.
Settings based on butt welds. Joint design, fitup, backup, position, bead size and stickout may alter conditions.