MIG and TIG settings by material thickness
One chart for the workshop wall: from material thickness to wire diameter, amps, volts, wire feed speed and gas flow. Next to it TIG, thin sheet and box section — all from the same data the site calculators use.
Short answer
5–6 mm plate, MAG: 1.0–1.2 mm wire, 160–220 A, 22–25 V, gas 14–16 l/min. TIG on 3.0 mm: 2.0–2.4 mm tungsten and 90–130 A DC.
MIG/MAG on steel by thickness
Values for solid wire on non-alloy steel in M21 gas (argon with 18 % CO₂), flat position. Wire feed speed is worked out with the formula of the wire feed calculator for the larger diameter in the range — the number you set on a machine without synergic control.
| Thickness, mm | Wire, mm | Current, A | Voltage, V | Wire feed, m/min | Gas, l/min |
|---|---|---|---|---|---|
| 0.8–1.0 | 0.6–0.8 | 40–70 | 15–17 | 1.5–4 | 8–10 |
| 1.5–2 | 0.8 | 70–110 | 17–19 | 4–7 | 10–12 |
| 3 | 0.8–1.0 | 110–150 | 19–21 | 4.5–6.5 | 12–14 |
| 5–6 | 1.0–1.2 | 160–220 | 22–25 | 4.5–6.5 | 14–16 |
| 8–10 | 1.2 | 220–280 | 26–29 | 6.5–8.5 | 16–18 |
| 12+ | 1.2–1.6 | 280–350 | 29–32 | 4.5–6 | 18–20 |
Feed speed is given for the larger wire in the range; a thinner wire at the same current runs faster.
TIG on DC− for steel
Tungsten on the negative pole, pure argon shielding. The filler rod is usually close to the tungsten in diameter.
| Thickness, mm | Tungsten, mm | Current DC−, A | Filler, mm | Argon, l/min |
|---|---|---|---|---|
| 0.5–1.0 | 1.0–1.6 | 20–50 | 1.0–1.6 | 5–7 |
| 1.5–2.0 | 1.6 | 50–90 | 1.6 | 6–8 |
| 3.0 | 2.0–2.4 | 90–130 | 2.0–2.4 | 7–9 |
| 4.0–5.0 | 2.4 | 130–180 | 2.4–3.0 | 8–10 |
| 6.0–8.0 | 3.2 | 180–250 | 3.0–4.0 | 10–12 |
Thin sheet 0.8–2 mm: three processes side by side
Below 2 mm every amp counts, so this is where to compare which process gives a weld without burn-through.
| Thickness | MMA | MIG/MAG | TIG |
|---|---|---|---|
| 0.8 mm | not recommended | 0.6 mm · 40–55 A · 15–16 V | tungsten 1.0 mm · 25–40 A |
| 1.0 mm | 2.0 mm · 50–65 A | 0.6–0.8 mm · 45–65 A · 16–17 V | tungsten 1.0 mm · 30–50 A |
| 1.5 mm | 2.0 mm · 55–70 A | 0.8 mm · 70–90 A · 17–18 V | tungsten 1.0 mm · 45–70 A |
| 2.0 mm | 2.5 mm · 70–90 A | 0.8 mm · 90–110 A · 17–19 V | tungsten 1.6 mm · 70–100 A |
Box section by wall thickness
The thinnest walls are stick welded only with stitch welds: a continuous run burns through the section.
| Wall, mm | Section | MIG/MAG | MMA |
|---|---|---|---|
| 1.2 | 20×20, 20×40 | 0.8 mm · 50–70 A · 16–17 V | 2.0 mm · 50–65 A, stitch welding |
| 1.5 | 40×20, 40×40 | 0.8 mm · 70–90 A · 17–18 V | 2.0 mm · 55–70 A, stitch welding |
| 2.0 | 40×40, 60×40 | 0.8 mm · 90–110 A · 17–19 V | 2.5 mm · 70–90 A |
| 3.0 | 60×40, 80×40 | 0.8–1.0 mm · 120–140 A · 19–21 V | 3.2 mm · 90–120 A |
| 4.0 | 80×40, 100×50 | 1.0 mm · 140–170 A · 19–21 V | 3.2 mm · 110–140 A |
Stick electrode
Current for 1.6 to 6 mm electrodes in every position is in a separate table:Current vs electrode diameter.
How to set the machine from the chart
Start in the middle of the range and run a test bead on scrap of the same thickness. A steady crackle means voltage and wire feed are matched; popping and spatter mean too little voltage or wire too fast; a long hissing arc means too much voltage. Keep the stick-out at 10–15 wire diameters.
Work it out for your job
The chart is a starting point. The exact feed speed for your current, gas use and a ready pWPS come from the calculators:
Frequently asked questions
What current for 0.8 mm wire?
On 1.5–2 mm sheet 0.8 mm wire runs at 70–110 A and 17–19 V; on 3 mm it takes 110–150 A. On the thinnest sheet 0.6 mm wire works better.
Do these settings suit a synergic machine?
Yes, they are just used differently: the synergic program sets voltage from wire feed, so take the wire size and current for your thickness from the chart and trim voltage by 1–2 V by the sound of the arc.
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