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:
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
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
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
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
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
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:
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
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
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
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
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
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
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
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
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
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:
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
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
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
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
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:
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
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
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
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
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
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
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.