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.
Reading a MIG/MAG row: the 5–6 mm example
The row gives 1.0–1.2 mm wire, 160–220 A, 22–25 V and 14–16 l/min of gas. Read it in this order:
- Wire. Of the two sizes, the thinner one runs better in the lower part of the current band, the thicker in the upper part. Set the feeder for whichever is in the machine.
- Amps → wire feed. On a non-synergic machine you do not set current directly — you set wire speed. For the middle of the band, 190 A, the wire feed calculator formula gives 8.5 m/min with 1.0 mm wire and 5.5 m/min with 1.2 mm. The column in the chart is worked out for the thicker wire.
- Voltage. Start in the middle of the band and trim by sound (see the set-up section below).
- Gas. 14–16 l/min is 840–960 litres per hour of arc-on time when welding continuously. How many cylinders a job takes comes from the gas consumption calculator.
The voltage tells you the transfer mode. Short-circuit is 16–22 V, globular 22–26 V, spray from 26–28 V. The 8–10 mm row (26–29 V) and the 12+ row (29–32 V) are already spray: flat position and PB fillets. The top of the 22–25 V band for 5–6 mm runs into the globular range, so at this thickness you either work in the lower part of the band or go up into spray.
Position. The chart is for the flat position. Vertical and overhead stay in short-circuit — in practice on the 3 mm row (0.8–1.0 mm, 110–150 A, 19–21 V) — and thicker plate is filled with more passes. Details: vertical-up welding, overhead, horizontal.
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 |
Reading the TIG table: two examples
3.0 mm sheet: 2.0–2.4 mm tungsten, 90–130 A (DCEN), 2.0–2.4 mm filler, 7–9 l/min of argon. Start at the bottom of the current band and raise it until the pool quickly wets both edges. 1.5–2.0 mm sheet: 1.6 mm tungsten, 50–90 A, 6–8 l/min of argon — on thin sheet travel speed matters more than current.
The tungsten size has to suit the current: too thin and it melts back, too thick and the arc wanders at low amps. Sizing and grinding are covered by the tungsten electrode calculator, the whole technique by the TIG guide.
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 · 50–70 A |
| 2.0 mm | 2.5 mm · 70–90 A | 0.8 mm · 90–110 A · 17–19 V | tungsten 1.6 mm · 70–90 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 |
Thin sheet and box section: choosing a process from the chart
1.5 mm sheet — three options on one row: MMA 2.0 mm · 55–70 A, MIG/MAG 0.8 mm · 70–90 A · 17–18 V, TIG 1.0 mm · 50–70 A. Stick is possible but the hardest: the chart gives a 2.0 mm electrode here and does not recommend MMA at all for 0.8 mm. MIG is the fastest, TIG the most controllable. Rules for welding without burn-through: welding thin metal.
2.0 mm box section (e.g. 40×40, 60×40): MIG 0.8 mm · 90–110 A · 17–19 V, stick 2.5 mm · 70–90 A. At 1.5 mm wall the stick column (2.0 mm · 55–70 A) adds stitch welding — a continuous run burns through the section. The weld order that keeps the section straight is in welding box section.
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 in short arc, longer in spray.
Setting up step by step
- Non-synergic: wire speed first (it sets the current), then voltage. After a test bead change one thing at a time: wire feed by about 0.5 m/min, or voltage by a small step.
- Synergic: choose the program (wire, gas), set thickness or wire speed from the chart, and only trim the voltage by 1–2 V by ear.
- Test on scrap of the same thickness, in the same position as the real weld.
Symptom → what to change
- Crackling and spatter, wire stubbing into the pool — too little voltage or wire too fast.
- Long hissing arc, a ball on the wire tip — too much voltage.
- Tall, narrow bead, toes not wetted — too cold: more current (wire) and voltage together.
- Burn-through — drop one row in the chart or travel faster.
- Porosity — check the flow is within the gas column, there is no draught and the plate is clean.
- Nice-looking face but unfused toes on thick plate — short-circuit is too cold for that thickness; more passes or a higher row. The defect is lack of fusion.
The stick electrode current table for every position is separate, and the position factors are explained on the welding positions page.
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.
What wire feed speed at 190 A?
By the wire feed calculator formula: 8.5 m/min with 1.0 mm wire and 5.5 m/min with 1.2 mm. At the same current a thinner wire feeds faster.
What settings for 2 mm wall box section?
MIG: 0.8 mm · 90–110 A · 17–19 V. Stick: 2.5 mm · 70–90 A. At 1.5 mm wall stick welding is done in stitches.
Can the MIG/MAG chart be used vertical and overhead?
Not directly: the chart is for the flat position. Out of position stay in short-circuit (3 mm: 110–150 A, 19–21 V) and add passes rather than raising the settings.
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