Whether you’re a professional welder or just starting to get your welding skills off the ground, having the right type of MIG welding wire is essential.
Different types of wires provide different results, but with so many options available, it can be hard to know which is best for your project.
If you’re feeling a bit overwhelmed, don’t worry! In this article, we’ll break down the ins and outs of different types of MIG welding wires.
Let’s get started!
Contents
MIG welding wire types: overview
All arc welding processes utilize filler metal. To make sure you get the right type of wire for the job, it’s important to know the available different types. Here’s a quick guide to all the types of MIG wires.
- Solid MIG wires
Solid wire is one of the most common types of MIG wires. This type of welding wire is often used for general welding on mild and medium-strength steels. It can also be used for aluminum and steel, but other types might work better for these specific metals.
- Flux Cored Wire
Flux-cored wires are similar to the solid wire but have a flux core inside rather than a smooth sheath on the outside.
The flux-cored wires help protect surrounding material from oxidation, so they can be used in areas where there are not enough fumes to keep oxidation at bay. It’s also often used in hard-to-reach or tight spaces where fumes cannot reach to complete your weld.
- Stainless Steel MIG Wire
Stainless steel wire is specifically designed for use with stainless materials, as it has been specifically made with higher levels of chromium and nickel content that allow it to handle extreme conditions (such as high heat). You’ll need stainless wire if you want to do any sort of welding work on stainless alloys or components.
- Aluminum Wire
Aluminum MIG wire is made with aluminum alloy materials and will give you improved welding arc characteristics compared to other weld wires when you’re doing aluminum wire welding projects.
Solid MIG welding wire: guide
Solid MIG welding wires are one of the most common types of welding wires in use today and are ideal for a range of projects. It consists of a solid, single-strand metal filler rod, usually made of copper or steel alloy.
It produces continuous welds without the need for shielding gas, making it exceptionally convenient for those who don’t have access to a shielding gas hookup.
Solid MIG wire works well with steel and aluminum materials. It’s also highly versatile and can be used on thinner metals such as 16 or 18-gage sheet metal up to thicker plates over an inch thick.
You can also select different sizes depending on what you’re welding, ranging from 0.023” to 0.045” in wire diameter.
Overall, solid MIG welding wire is an excellent choice if you’re looking for reliable performance that won’t break your budget — and it comes in both spooled versions or cut lengths that are ready to go right out of the box!
Flux cored wire: what you need to know?
The second type of MIG welding wire is flux-cored wire. Flux-cored wires are easy to use and provide an excellent weld, making them a popular choice among welders. This type of wire requires relatively less time to set up and offers a higher deposition rate compared to solid wire.
Flux-cored arc welding has the additional benefit of being able to be done in any position, which makes it suitable for a wide range of applications. Nevertheless, as compared to TIG and stick welding, flux core wires might generate more smoke and fumes, therefore enough ventilation is required.
Moreover, TIG welding and stick welding procedures do not require an external gas cylinder and do not necessarily require shielding gas or electrodes, since cored wires are self-shielded.
Overall, flux-cored wires are great for use in thicker materials and welding in difficult-to-reach areas, as well as offering greater efficiency than solid wires.
Compared to solid wire, flux-cored wire enables the welder to employ greater amperages and larger diameter wires. It is important to note that this type of MIG wire cannot be used with aluminum or other nonferrous metals.
Stainless steel MIG wire for specialty work
If you’re looking for a type of wire that can handle some specialty work, then a stainless wire is for you. Not only is it incredibly versatile, but it can also handle high temperatures better than other types of wires and is rust-proof, making it a great choice for welding in wet or humid conditions.
So what exactly makes stainless wire so special? Let’s dive into the details:
- Super Strength
This type of wire can take on extreme temperatures and wear, making it great for construction and similar applications.
- Heat Resistant
Steel wire won’t burn up like regular wires, so it’s great for welding different metals such as mild steel and aluminum.
- Non-corrosive
This type of MIG welding wire won’t corrode like other types of metal in environments with high humidity or moisture levels.
Plus, since the awesomely strong welds dons when using this type of wire are highly resistant to corrosion and oxidation, they’re an excellent choice for welding near bodies of water or in other wet environments.
Benefits of aluminum MIG wire
Aluminum wire is a great choice for many welding jobs due to its high strength and low price. Aluminum is highly conductive and will reduce spatter, provide superior arc stability, and also minimize distortion compared to other metals.
But that isn’t all — this kind of wire also has several other benefits:
- Lightweight yet strong. Compared with regular steel wire, aluminum wire is much lighter, making it easy to transport and use in welding projects.
- Resistant to corrosion. Due to its natural layer of aluminum oxide, the wire does not require any additional coatings or treatments for corrosion resistance.
- Cost-effective. Aluminum MIG wires are cheaper than alternative options like copper, making them one of the most cost-effective solutions for your welding project.
Gasless flux core wire for beginners
If you’re a beginner at welding, then you’d want to check out gasless flux cored wire. As opposed to solid wire electrodes or tubular wires, this type of wire does not require a shielding gas when the wire melts.
In other words, all you need is the flux core wire instead of having to go through the hassle of handling and applying shielding gas to protect the molten weld pool from oxidation.
Not only is this type of wire more affordable than other types of MIG welding wire, but it’s also much more convenient.
And don’t worry — this flux core wire still provides good results, with satisfactory weld beads and good joint strength. Flux wire is often used for home workshop projects and DIY jobs, making it the ideal form of wire for those who are just starting in welding.
To make sure you get a good result with your welding project, there are a few key points to remember:
- Make sure you get the right size and thickness according to your project’s requirements.
- Take extra care of the wire feed mechanism as that makes all the difference in terms of your weld bead’s quality.
- Choose the right technique depending on what kind of surface or material you’re working on.
Tubular and hard wires: for heavy use
Tubular wires and hard wires are the specialty options when it comes to MIG welding. They’re used in metalworking and heavy fabrication, where an extra-strong weld is needed.
- Tubular wire
Tubular wires are made with tubular metal cored wire that’s filled with fluxing agents, deoxidizers, and metal alloys. Tubular wires also prevent spatter and can be used in all positions due to their low melting point.
- Hard wire
Hard wire is a thicker wire that is great for welding thicker metals, because of its high voltage characteristics. The thicker the wire, the higher the voltage and power of the MIG machines. While dealing with a low-power MIG welder, thicker wire is not recommended.
You should always take the metal’s thickness into account to select the right MIG welding wire thickness. The maximum suggested wire thickness should always be found in the manufacturer’s specifications.
This type of wire is known for its strength and for its ability to weld metal creating a smooth weld that won’t crater or show any thinning in the material. The shape of the welding gun arc it creates helps to reduce splatter, too.
So if you need a strong weld that will stand up to extreme temperatures or heavy loads over time, tubular and hard wires are your best bet.
You won’t be disappointed — these two welding wire types are as tough as nails!
To learn more about what is welding wire, and what types are there, check out this post here.
Conclusion
When it comes to selecting the wire for your next welding machine job, selecting the appropriate MIG welding wire is essential. Keep in mind the type of job you are doing and the grade or type of material you are welding, as well as the environment you are welding in. Choose the right wire and you will get the best results possible.
Whether you are using a solid wire or flux-cored wire, aluminum, or copper coating even a gasless flux-core wire, understand the differences between each type of wire and make sure to select the best one for the job.
With this in mind, you can make sure you’re using quality MIG wire and get the best results each time.
FAQ
How does the minimum tensile strength relate to different types of MIG welding wires?
Minimum tensile strength is an important factor when choosing MIG welding wires. It refers to the amount of stress a welded joint can withstand before breaking. For mild steel, common grades with different minimum tensile strengths include ER70S-3 (62,000 psi) and ER70S-6 (70,000 psi).
What are the different types of MIG welding wires?
MIG welding wire comes in two varieties: solid wire and cored wire. Welding using solid wires is most commonly used for mild steel, stainless steel, and aluminum. Flux-cored wires are available in two varieties: gas-shielded and self-shielded and are used for welding heavier metals when shielding gas is impracticable.
What are the grades of MIG welding wire?
The type of metal being fused largely determines the grade of welding wire used for MIG welding. Mild steel grades such as ER70S-3 and ER70S-6 are prevalent.
Grades of stainless steel utilized include ER308L, ER309L, and ER316L. ER4043 and ER5356 are two aluminum welding wire grades. The grade selected is determined by the composition of the base metal and the required welding qualities.
If you need to read about welding rod sticking, please read our article.
