Some MIG welders handbook: how to become a more skilled welder and how to choose the best welding equipment. For DCEN welding on steels, 1/16″ will work in the 20 to 100 amp rage as long as you prep it right. If you are using 20 amps, you will need a needle sharp point to get good crisp arc starts. At 100 amps, you might not want quite a needle sharp point or you might be putting a smidge of tungsten in the weld. You need a blunter taper. Some charts extend the range to 150 amps for 1/16, but I think that’s way too much. Why not just swap to a 3/32 at that amperage.? 3/32″ is good from about 65 – 200 amps. And 1/8″ 2% thoriated electrodes are good in the 85 – 300 amp range. ( Drop all these numbers by about 30% for A/C) Using helium mixed with the argon will also change the recommended currents because the arc is hotter with the same amps. These recommendations are from down and dirty experience and don’t come from a chart. Most charts I have seen tell you a 1/16 tungsten is good all the way to 150 amps…Please.
TIG welding filler wire and Mig welding wire from a spool are essentially the same composition except that mig welding wire often contains more silicon and that can actually be a good thing for TIG welding steel. Don’t hesitate to use steel or stainless steel mig wire if you run out of TIG welding filler metal. If its too small, double it up and twist it up in a cordless drill. Standard Tig wire for welding mild steel is E70S2 It seems like the standard mig welding wire off the shelf these days is almost always E70S6. The 2 and the 6 indicate the addition of silicon and deoxidizers in the wire. Stainless tig and mig wire is most often E308L unless you ask for something else.
Look for ways to support your hands. Having good support for your hands or arms is crucial for moving the torch with precise control. I do my best welding when the base of my hands or my wrists is supported in some way. Often you can rest your wrists on the part being welded. I keep an assortment of wood and metal blocks near my welding bench, and I often can get better support by positioning a block to rest my torch hand on. There are occasions where I rest my forearms, or even my elbows, on something for support. Many welders set up special support bars, positioned parallel to the joint being welded, and they slide their torch hand along the bar to help follow the joint with fine control. For some out-of-position work, I’ve had to rely on resting only my shoulder on something, and while not ideal, it’s better than having no support at all. Even placing my hip against something stationary can offer a bit of support, but I can’t weld very well when standing ‘free,’ with no support at all.
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Always know what gas your wire requires — whether it’s 100 percent CO2 or argon, or a mix of the two. \While CO2 is considerably cheaper than argon and good for penetrating welds on steel, it also tends to run cooler, making it usable for thinner materials. Use a 75 percent argon/25 percent CO2 gas mix for even greater penetration and a cleaner weld, since it generates less spatter than straight CO2. Here are some suggestions for shielding gases for common types of wire: Solid Carbon Steel Wire: Solid carbon steel wire must be used with CO2 shielding gas or a 75 percent CO2/25 percent argon mix, which is best used indoors with no wind for auto body, manufacturing and fabrication applications. Aluminum Wire: Argon shielding gas must be used with aluminum wire, which is ideal for stronger welds and easier feeding. Stainless Steel Wire: Stainless steel wire works well with a tri-mix of helium, argon and CO2.