How to Choose the Right MIG Welding Wire for Mild Steel

MIG welding also known as metal inert gas is a very well-known procedure of welding. This method is used to melt mild steel. In this process, a continuous wire feed is used to join the two pieces of metal together. To carry out this welding process, you should choose the best and right welding wire.

Choosing the correct wire is essential for achieving clean and strong welds. This MIG welding wire is made of consumable metal that melts. This melting joins the metals together when it is provided by an electric arc.

The welding gun is then used to feed the wire to protect the arc and the wire from the atmosphere. The two types of MIG welding wires are: solid wire (ER70S) series and flux cored wire (E71T) series. Solid wire welding is best for producing clean and precise welds.

On the other hand, flux-cored wire is used for welding on rusty surfaces. Wire diameter and thickness vary from material to material and choosing the wrong diameter wire produces ineffective results. In order to protect the weld from contamination, shielding gas is required. Usually 100% CO2, 75% Argon or 25% CO2 are used to produce clean and strong welds.

The welding process is used in various industries like automation, manufacturing and construction. In this section, we will explore how to choose the best wire for MIG welding, their characteristics and applications. By choosing the best wire you will be able to make informed decisions.

Understanding MIG Welding Wire

MIG welding wire is a very important part of this welding process. It is a thin continuous metal wire that is used to join two metal pieces together. This wire can be made with a variety of different metals like aluminum, steel and manganese. By drawing metal into thin wire you can make this wire. Then it is wound onto the reel.

Types of MIG Welding Wire

Solid wire:

It is the smooth and most common MIG welding wire. This wire is designed to melt and join the metal pieces together.

Characteristics of solid wire welding:

This produces clean and smooth welds with minimum splatter.
It is very easy to use.
It is less expensive than the flux-cored wire.
It is best for thin metals such as sheet metals.

Flux cored wire:

This welding wire has a flux core at its center. This protects the arc and the wire from the atmosphere. During this process, the flux core is burned and it produces a shielding gas that stops the air from entering the welding pool.

Characteristics of flux-cored welding wire:

It produces very high-quality welds with minimum slags.
It is more expensive than solid wire welding.
It works best on thicker metals by providing good and deep penetration.

Characteristics of MIG Welding Wire

Wire diameter:

The amount of heat generated during welding depends upon the wire diameter. If the wire used is thick, then it will generate more heat and if the wire is thin it generates less heat.

Wire composition:

The composition of a wire plays a very important role in its strength, durability and corrosion resistance. Different wire compositions depend on the different welding applications.

Shielding gas compatibility:

There are specific shielding gases such as argon and carbon dioxide. These gases help in improving the quality of the weld.

Tensile strength:

The ability of the metal to withstand pressure and stress is called tensile strength.

Melting point:

The melting point of the wire will tell us for how long the wire will melt to ensure a quick process.

How to Choose the Right MIG Welding Wire for Mild Steel?

When dealing with MIG welding wire, there are two main types of wires:

1- Solid MIG Wire(ER70S-3 or ER70S-6):

ER70S-3:

This wire is best for producing clean and strong welds.
It produces smooth steel.

ER70S-6:

It is best for steel having rust, dirt or mill scale.
It has more deoxidizers in order to clean the metal during the welding process.
It requires shielding gas 75% Argon, and 25 %CO2 gas mix for spatter-free welds.

2- Flux cored wire (E71T-GS or E71T-1):

It does not require any shielding gas.
It is best for thicker mild steel.
It is ideal for working in outdoor and windy conditions.

Determine the thickness of the metal:

You have to figure out the thickness of the metal while welding. For example, for thin metals use a 0.023-0.030 wire. For thicker metals use 0.035-0.045 inch wire.

Choose the right wire type:

Choose the right shielding gas:

If you want to get cleaner welds with less spatter use 75% Argon and 25%CO2 with it. It is most recommended.
If you use 100%CO2 it will create more penetration and more spatter.
If you are dealing with structural welds use this.

Matching wire with welding machine settings:

The top factors are voltage, wire feed speed and shielding gas flow rate.

Adjusting voltage:

The voltage is used for controlling heat and penetration. Low voltage is needed for thin metal and higher voltage is needed for thicker metals.

Wire diameter and metal thickness determine the voltage settings.

Setting the wire feed speed:

Wire feed speed controls how much wire is melted. If the speed is too fast, it can cause more spatter and poor fusion. If it is too slow, it can cause weak welds to have gaps.

Shielding gas flow rate:

If there is too little gas, it can produce weak welds. On the other hand, if it is too much, it can cause turbulence.

Tips for storing MIG Welding Wire

Try to keep the wire dry. This will prevent rust.
Keep the wire away from humidity.
To protect the unused wires, use plastic bags or sealed containers.
Deal wire with clean hands to avoid dirt, and oil from damaging it. Handle the wire using gloves and avoid placing it on greasy surfaces.
Store it at room temperature.
Use wire covers to protect the wire from debris.

Conclusion

If you want to produce strong and clean welds, then considering the right MIG welding wire is very crucial. Solid wire is used for slightly dirty or clean metals. The flux cored wire works ideally for outdoor welding without needing any shielding gas. The wire diameter and shielding gas also play a very important role. By reading and understanding the factors above you can create welds with fewer defects.