Different applications also require Different MIG Welding Wire Types
One of the most commonly employed welding techniques in industries like automotive repair to structural fabrication is **Gas Metal Arc Welding (GMAW/MIG)**. This process is adaptable as it involves a consumable solid wire fed through a welding gun and broken down by an electric arc, in the weld pool to form a joint. A shielding gas is used to protect the weld from atmospheric contamination.
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Though the fundamentals of (Gas Metal Arc Welding)GMAW/MIG are universal, MIG welding wire comes in many types depending on how much tensile strength is needed. In this post we will explore the various types of MIG welding wire that are available and help you determine which to choose for your job.
What is a Gas Metal Arc Welding (GMAW/MIG)
Gas Metal Arc Welding (GMAW/MIG) – Is a process where an electric arc is formed and maintained between the wire electrode and base material, while heat needed to melt metal from wire fills them when melted. The process is quite easy to learn, and hence one of the most favored choices for beginners as well as professionals in the welding industry. It works for assorted materials such as mild steel, stainless steel, and aluminum; metal industries like automotive, construction, manufacturing.
Common Sizes — MIG Welding Wire Types
These include a wide range of compositions and diameters for MIG welding wires, which are specifically selected depending on the type of metal to be welded as well as the application. In **Gas Metal Arc Welding (GMAW/MIG) welding,** the most common types of MIG welding wires included are:
#### 1. **ER70S-6 (Carbon Steel Wire)**
Among the **Gas Metal Arc Welding (GMAW/MIG)** Welding wire, ER70S-6 is considered one of the standards which is used mostly. A cleaner weld with fewer impurities is produced by this carbon steel wire which has higher silicon and manganese compared to other wires. ER70S-6 is designed for welding mild steel of 55,000 psi tensile strength (the manual recommends working with materials in the.030” -.035” range) and can be used as either an MIG or flux core wire.
– **Applications**: Widely used for welding mild steel in industries such as automotive repair, shipbuilding and manufacturing. It is effective in both single-pass welding and multi-pass welding.
– **Benefits**: With ER70S-6, you will get great arc stability and bead appearance for clean finishes with minimal spatter.
#### 2. ER308L (stainless steel wire)
When it comes to stainless steel projects, ER308L is a prefered option. This wire is to be used for welding Type 304 and 304L stainless steels. The “L” means that the material is a lower carbon content to help reduce carbide precipitation in the weld and low-corrosion resistance.
– **Common applications**: ER308L is predominantly used in the food and beverage industry, where corrosion resistance makes it a necessity as well as chemical plants. In addition, it is employed in making tanks and piping for the stainless steel equipment sector.
– **Pros**: This wire delivers excellent corrosion resistance and is suitable for any place where stainless steel might be required due to its ability to weld.
#### 3. **ER4043 (Aluminum Wire)**
ER4043 — Used in MIG welding aluminum. A 4 per cent silicon aluminum wire used for welding various grades of aluminum, including the ferrous-free Aluminum-manganese alloys such as 3003 and wrought plate from reference points like a projecting wall-plate to other Al-Mg or mixed joints on hull-building. Silicon helps to lower the chances of cracking during welding, which is an issue when it comes to aluminum.
– **Applications**: ER4043 finds its usage in many fields, including aerospace and auto marine applications where aluminum parts are required to be welded. It is particularly effective for aluminum sheet and casting welding.
**Pros**: The silicon in the wire makes it smoother when welding and you get more aesthetically pleasing welds.
#### 4. **E71T-1 (Flux-Cored Wire)**
Flux-cored wires such as E71T-1 are not exactly solid wire (which is used in GMAW/MIG welding), and they do behave that way. This wire uses a flux core which means there is no requirement for additional shielding gas in some cases but it can also be run with the extra gasses to give the best results. Common for Outdoor welding or deep penetration with thick base materials.
– **Applications**: E71T-1 is used a lot in heavy structural welding, and shipbuilding as well as for repair work on tractors. It will also weld through rust, dirt, and mill scale making it ideal for outdoor use.
– **Benefits**: This wire type offers many advantages, such as good mechanical performance and high deposition rates. It is great to use when the preparation of a surface before paint becomes epoxy application.
Selecting MIG Wire According to Application
There are many different types of MIG welding wires to choose from, and the type you select should be based on what material will have been mig-welded as well as how thick that process weld is — not even counting other factors for specific applications. Here are some features you may wish to consider:
- **Base Metal Composition****:** Selecting a welding wire that is incompatible with the material you are working on. A 75%Ar -25%C shielding gas and an ER70S-6 wire are a good example for welding mild steel. ER308L for stainless steel and ER4043 for aluminum.
- **Material Thickness**: The thicker the material, typically the larger diameter wire you will want to use so as not burn though unless maximum penetration is wanted. Flux-cored wire (such as E71T-1) can be especially useful in thicker materials and outdoor applications where the wind may move shielding gas away.
- **ESTIMATE: Weld Position **— Some wires have characteristics that are better suited in certain welding positions (flat, vertical up, overhead). That is, slag-forming characteristics of flux-cored wires can oftentimes make them simpler to use when welding vertical or overhead.
- Shielding Gas: The shielding gas you use can have an impact on the way your weld turns out. ER70S-6 and ER308L are often used with argon-CO2 mix, whereas AL wire – like ER4043 should be used solely on pure argon. Flux-cored wires such as E71T-1 may not need any gas while others can see improvements from using a shielding gas.
### Conclusion
For the highest quality welds in **Gas Metal Arc Welding (GMAW/MIG)**, it is imperative to know & understand what type of MIG welding wire you are working with. Whether you are working with carbon steel, stainless steel or aluminum the wire chosen can mean a great deal for reliability and strength of your welds. From ER70S-6 for mild steel to the popular ER4043 for aluminum, each wire type has unique advantages that they bring to specific applications Remember to select the right MIG wire and your welds will always be strong, clean, and reliable.
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