MIG Wire Settings: A Guide to .035" Wire
When it comes to MIG welding, having the right wire settings is crucial for achieving high-quality welds. In this article, we'll focus on the settings for .035" MIG wire, a popular size used for various welding applications.
What is .035" MIG Wire?
.035" MIG wire is a type of welding wire with a diameter of 0.035 inches (0.89 mm). This wire size is commonly used for welding thin metals, such as automotive body panels, mild steel, and aluminum. The smaller diameter of the wire allows for more precise control and better penetration in thin materials.
Wire Feed Speed (WFS) Settings
The Wire Feed Speed (WFS) is the rate at which the wire is fed into the welding gun. The ideal WFS for .035" MIG wire depends on the type of metal being welded, the welder's skill level, and the desired weld quality. Here are some general guidelines for WFS settings:
- Mild Steel: 100-140 inches per minute (ipm) for 1/4" thick material, and 140-180 ipm for 1/8" thick material.
- Aluminum: 120-160 ipm for 1/4" thick material, and 160-200 ipm for 1/8" thick material.
Voltage Settings
The voltage setting determines the heat input into the weld. For .035" MIG wire, the ideal voltage setting depends on the type of metal being welded and the desired weld quality. Here are some general guidelines for voltage settings:
- Mild Steel: 18-22 volts for 1/4" thick material, and 20-24 volts for 1/8" thick material.
- Aluminum: 20-24 volts for 1/4" thick material, and 22-26 volts for 1/8" thick material.
Shielding Gas Settings
The shielding gas setting determines the amount of gas used to protect the weld area from atmospheric gases. For .035" MIG wire, the ideal shielding gas setting is:
- Argon/CO2 Mix: 75-90% Argon, 10-25% CO2
- Flow Rate: 20-30 CFH (cubic feet per hour)
Tips and Tricks
- Always use a high-quality MIG wire that is designed for the specific metal being welded.
- Maintain a consistent wire feed speed and voltage setting to achieve a high-quality weld.
- Keep the welding gun at a consistent distance from the workpiece to maintain a stable arc.
- Use a shielding gas with a high argon content for welding aluminum to prevent porosity.
By following these guidelines for .035" MIG wire settings, you'll be able to achieve high-quality welds with excellent penetration and appearance. Remember to always follow safety protocols and use personal protective equipment when welding.
