Solid wire electrodes
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Frequently asked questions
Where is ER70S-6 wire used?
ER70S-6 under AWS A5.18 is the most common carbon steel solid wire, with minimum tensile strength of 70 ksi, about 490 MPa. Its higher manganese and silicon content deoxidizes well and tolerates light mill scale or oil. It runs with CO2 or argon and CO2 blends.
Should I use CO2 or an argon and CO2 blend?
Pure CO2 is cheaper and gives deep penetration but more spatter and a rougher bead. A blend of about 80% argon and 20% CO2 gives a smoother arc, less spatter and a better bead. Carbon steel solid wire runs DC electrode positive with either gas.
How do I choose wire diameter?
0.8 mm wire suits thin sheet and low current, 1.0 mm and 1.2 mm are the most common in fabrication, and 1.6 mm suits high current on thick plate. Wire diameter must match the drive rolls and contact tip. A wrong-size tip causes feeding jams or an unstable arc.
How does rust on welding wire affect results?
Rust on the wire causes porosity, uneven feeding and rapid contact tip wear. Keep spools sealed in a dry place, and cover a partly used spool on the machine during long stops. In humid climates especially, do not open the packaging well before use.
Which wire is used for MIG welding aluminum?
Common aluminum wires are ER4043 (silicon alloy) and ER5356 (magnesium alloy) under AWS A5.10, chosen by base alloy and color match after anodizing. Shielding gas is pure argon. Aluminum wire is soft, so it needs U-groove rolls, a plastic liner and ideally a push-pull or spool gun.
Which spool types and weights are available for welding wire?
MIG wire is commonly supplied on 15 kg plastic or K300 wire basket spools, with 5 kg spools for small machines. High-volume lines often use drums of 250 kg or more to cut changeover time. Check that the machine's spool hub fits the spool type.
How are drive rolls chosen?
Drive rolls must match the wire size: V-groove for solid steel wire, U-groove for aluminum so the wire is not crushed, and knurled for flux-cored wire. Roll pressure should be just enough to stop slipping, as excess pressure deforms the wire and causes jams in the liner. Worn rolls also cause erratic feeding.
Which wire is used for MIG welding stainless steel?
Stainless solid wires are classified under AWS A5.9, for example ER308LSi for 304 and ER316LSi for 316. The Si suffix improves pool fluidity and bead appearance. Shielding gas is usually argon with 2% CO2 or 2% oxygen, not pure CO2.
