Which size wire should I use?

[alrednek]

I just bought a Millermatic 251 to use in my home shop. I'm not exactly a newbie to welding, (I have done quite a bit of stick welding) but I have a lot to learn about mig welding. I plan to run C25 gas and mild-steel wire. I'll be welding mostly 1/8" to 1/4" thick structural shapes, and occasionally some thicker materials (up to about 1/2"). I will occasionally need to weld auto body panels also, which of course are very thin sheet metal. My question is: What would be the best size (diameter) wire for my intended usages? I bought a 44# roll of .035 wire today, but can swap it for .030 if it would be better. Which of these would be best for all-around use? Would it be better to just buy different size wire for each application? Any advice or suggestions are welcomed.

Thanks, Mike Hannah

[Ed Heimbach]

.035 is an OK choice for all-around welding, I wouldn't worry about swapping for smaller.
Now that I said this, I'm sure someone is going to tell you .030 is better, or .024, but I like it for general work, and I think you will too.

[Guest]

I'm with ya, Ed....035" for me. too.

[Dan]

Mike,
Generally, .035 works pretty good for 16 ga - 1/2". The 1/2" being done in multipasses. However, some people don t have the skill level yet to use .035 on 16 ga and they prefer .030 for this. Automotive sheet metal kinda depends on the machine and the operator. With my MM 210 I can easily weld this sheetmetal with an .030, but on my HH 135 or HH 175 you have to use an .023 wire. Now, I prefer to stock all three wire sizes in 10 or 12 pound rolls so I can set the machine up with the best wire size for the job.

Also, Mike if any of this 1/4" to 1/2" material is going to see any type of loading you seriously need to think about having a second bottle of gas around for spray transfer or use a gas shielded fluxcore with your C-25 or a third option would be a self shielded fluxcore wire. This is a topic for another thread or you can read up on it if you do a search on this site. Several of us have supplied quite a bit of info on this already.

[Scott V]

RockyD should of waited for one more answer.Dan has the right answer.

[Guest]

Originally posted by Scott V
RockyD should of waited for one more answer.Dan has the right answer.

You must've been flashed-burned, Scott...I wasn't answering a question...I was only agreeing with Ed....Dan does have an excellent answer, as he always does. For my skill level, as well as Ed's...we use .035" . Now go back to your dealership.

[Scott V]

RockyD,why not answer?Who knows,it might keep you busy for a while!(I hope)

[MYSTORES]

I agree.. .035 70S6 is a great automotive body shop wire.. Straight Co2 works fine with it.. and it will test out at 70,000 psi which is stronger than the 55,000 psi metal we are normally welding.. I don't like flux core for body work.. but it is good for heavier metals..and even better with gas..as an extra shielding. My .02 cents

[mark cunningham]

hi ans to your question,is use 0.8 for light metals and 1.0/1.2 for thicker steel ie 3mm to 25mm.i hope this will help you

[Guest]

Originally posted by mark cunningham
hi ans to your question,is use .030"for light metals and .045" for thicker steel ie 1/8" to 1" i hope this will help you

Welcome to the forum, Mark. I translated your measurements to inches, I hope you won't mind....glad to have your input!

[Hobart Expert Rock]

ALREDNECK...........WELCOME ABOARD.............AS YOU CAN SEE THERE ARE MORE THAN ONE ANSWER TO MOST QUESTIONS... MY GUESS IS THAT AFTER YOU PARACTICE AWHILE WITH ALL SIZES OF WIRE YOU WILL FIGURE WHAT WORKS BEST FOR YOU........ AND AS YOU PROGRESS AND GET BETTER WITH THE TECHNIQUE YOU WILL START TO USE LARGER WIRES..............AND DIFFERENT GASSES.............. PRACTICE IS THE KEY...........BE SAFE..... AND HOW DID YOU FIND THE SITE.................ROCK..................
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[Hobart Expert Rock]

HI MARK CUNNINGHAM..........WELCOME ABOARD AND THANKS FOR CHIMMING IN WITH US..............HOW DID YOU FIND THE SITE....... MANAGEMENT ALWAYS LIKE'S TO KNOW...............HAVE SOME FUN NOW,.........................ROCK................
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[alrednek]

Thanks guys...I appreciate all the replies. I'm still kinda unclear about whether I'll have the skill to use the .035 wire I bought. From what I've gathered from a couple of the replies it sounds like using the heavier wire (.035 vs .030) might require some mig experience and skill, of which I have VERY little at this point. Will I be able to use the .035 for general use right from the start, or should I start off with .030 and wait until I get the techniques down pat before moving up to .035? Or does the .005 really make a difference for general welding? I've decided to get a roll of .023 for welding the automotive panels...didn't want to have to change out rolls, but I'll probably be better off with the smaller wire until I get the hang of it.

As for Mark's question about how I found the site...I was referred from another board dealing with Machine Shop and metal machining topics (Machine Shop Forum). From what I've seen so far, the people on this board are just as helpful as the guys on the MS Forum...this is a very nice board indeed. I'll be asking more questions as I go along...

Mike Hannah

[MYSTORES]

Just start welding

Hello friend.. You'll do fine with .030...... .035.. 70S6 wire and CO2.. just take a panel ripper and cut up some wrecked door panels and practice writting your name on the back(clean side)of the door panel without burning thru.. I should think in less than an hour you'll have the hang of it.. You should get the HTP welding tape for welding body panels.. At $18.00 it is VERY helpful and will show you how to do everything you are asking about.. I've never run .023 wire.. and always thought it was for little welders.. I have run .035 bronze wire in the past with great results.and these guys here are a big help.. Hope this helps.. My the ARC be with you Mike

[cope]

For heavier metal, the .035 is better. .030 seems like a red-headed stepchild on some machines, but others like it. Once you decide which size you want, get the 12" spool.