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29
WELDING WIRE DIAMETER CHART
RECOMMENDED WIRE DIAMETERS
MATERIAL
THICKNESS
24 Gauge (.60mm)
22 Gauge (.75mm)
20 Gauge (.90mm)
18 Gauge (1.0mm)
16 Gauge (1.2mm)
14 Gauge (1.9mm)
3.0mm
5.0mm
6.0mm
8.0mm
10.mm
12.0mm
0.6mm 0.8mm 0.9mm 1.0mm
MIG SOLID WIRE GASLESS FLUX CORED WIRE
0.8mm 0.9mm 1.2mm
For material thickness of 5.0mm and greater, multi-pass runs or a beveled joint
design may be required depending on the amperage capability of your machine.
Wire types and sizes - Use the correct wire type for the base metal being welded. Use stainless
steel wire for stainless steel, aluminium wires for aluminium and steel wires for steel.
Use a smaller diameter wire for thin base metals. For thicker materials use a larger wire diameter
and larger machine, check the recommended welding capability of you machine.
As a guide refer to the “Welding Wire Thickness Chart” below.
Gas selection - The purpose of the gas in the MIG process is to protect / shield the wire, the arc
and the molten weld metal from the atmosphere. Most metals when heated to a molten state will
react with the air in the atmosphere, without the protection of the shielding gas the weld produced
would contain defects like porosity, lack of fusion and slag inclusions. Additionally some of the




Use the correct shielding gas. Co2 is good for steel and offers good penetration characteristics,

mixed gas. Argon Co2 mix gas offers better weld ability for thin metals and has a wider range of

applications.
Argon Co2 Co2
Penetration Pattern for Steel
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