Selecting the correct welding consumable — whether MIG wire or TIG filler rod — is critical to achieving strong, durable welds. Different steels have unique properties, from strength to corrosion resistance, and require specific filler materials to ensure the weld performs as intended.
The tables below provide quick references for common steel types, the recommended MIG wires and TIG rods, and the right diameters for different material thicknesses.
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Common Steel Types and Recommended Welding Wires & Rods
| Steel Type | MIG Wires | TIG Rods | Example Uses |
|---|---|---|---|
| Carbon Steel | ER70S-6, ER70S-3, ER70S-2 (MIG); E71T-1, E71T-11 (FCAW) | ER70S-2, ER70S-6 | Building frames, bridges, pipelines |
| Low-Alloy Steel | ER80S-D2, ER80S-G, ER100S-1 | ER80S-D2, ER90S-B3, ER110S-G | Heavy machinery, automotive, construction projects |
| High-Strength Low-Alloy (HSLA) Steel | ER80S-D2, ER100S-1 | ER100S-G, ER110S-G | Aerospace, automotive manufacturing, military equipment |
| Stainless Steel (Austenitic & Martensitic) | ER308L, ER309L, ER316L, ER347, ER410 | ER308L, ER309L, ER316L, ER347, ER410 | Food processing, medical instruments, chemical processing |
| Duplex Stainless Steel | ER2209, ER2307, ER2594 | ER2209, ER2594 | Chemical/petrochemical processing, oil & gas, marine |
| Nickel-Based Alloys | ERNiCrMo-3, Inconel 625, Inconel 718, Monel 400, Hastelloy C-276 | ERNiCrMo-3, ERNiCr-3, ERNiCu-7 | Aerospace, power generation, chemical processing |
| Tool Steel | E312, ENiCrMo-3, tool-steel-specific wires | ER312, nickel-based TIG fillers | Repair of dies, molds, cutting tools |
| Cast Iron | ENiFe-CI, ENi-CI; ⚠️ E6013 only for cosmetic patch repairs | ERNi-CI, ERNiFe-CI | Engine blocks, pump housings, machinery repairs |
Recommended Wire & Rod Diameter by Material Thickness
| Material Type | Material Thickness | Typical Wire Diameter (MIG) | Typical Rod Diameter (TIG) | Notes |
|---|---|---|---|---|
| Mild / Carbon Steel | < 1.5 mm (sheet) | 0.6 – 0.8 mm | 1.0 – 1.6 mm | Small diameters minimise burn-through. |
| 1.5 – 6 mm | 0.8 – 1.0 mm | 1.6 – 2.4 mm | Standard for automotive & general fabrication. | |
| 6 – 12 mm | 1.0 – 1.2 mm | 2.4 – 3.2 mm | Higher amperage for deeper penetration. | |
| > 12 mm | 1.2 – 1.6 mm | 3.2 – 4.0 mm | Heavy structural steel and thick plate. | |
| Stainless Steel | < 3 mm | 0.8 – 1.0 mm | 1.6 mm | Controls heat input, reduces distortion. |
| 3 – 6 mm | 1.0 – 1.2 mm | 2.4 mm | Common in food/chemical plant work. | |
| > 6 mm | 1.2 – 1.6 mm | 3.2 mm | Often TIG root + MIG fill. | |
| Aluminium | < 3 mm | 0.8 – 1.0 mm | 1.6 mm | Use spool gun or push-pull for feeding. |
| 3 – 6 mm | 1.0 – 1.2 mm | 2.4 mm | Balance feedability & deposition. | |
| > 6 mm | 1.2 – 1.6 mm | 3.2 – 4.0 mm | Heavy aluminium plate, structural. | |
| Flux-Cored (Steel / Stainless) | 3 – 12 mm | 1.2 – 1.6 mm | – | Flux-cored wires run larger due to flux fill. |
| Nickel Alloys / Exotics | Varies | 0.9 – 1.2 mm | 2.4 – 3.2 mm | Must follow WPS & filler manufacturer. |
Quick Rules of Thumb
- Thicker metal → larger wire/rod diameter + higher amperage.
- Thin sheet metal → smaller diameters to avoid burn-through.
- Flux-cored wires typically start at 1.2 mm+.
- Machine capacity matters — smaller machines may max out at 0.8–1.0 mm wires.
- Always refer to
