MIG welding settings depend on material thickness, wire diameter, and shielding gas. This chart covers mild steel with ER70S-6 wire and 75/25 argon/CO2 mix, the most common setup in hobby and light fabrication shops.
Every value here is a starting point. Your machine, joint configuration, and welding position all affect the final settings. Run a test bead on scrap before committing to your workpiece.
MIG Welding Settings by Material Thickness
| Material Thickness | Wire Diameter | Voltage (V) | Wire Speed (IPM) | Gas Flow (CFH) | Amperage Range |
|---|---|---|---|---|---|
| 24 ga (0.024") | 0.023" | 15-16 | 100-150 | 15-20 | 30-50 |
| 22 ga (0.030") | 0.023" | 15-17 | 120-170 | 15-20 | 35-60 |
| 20 ga (0.036") | 0.023" | 16-17 | 150-200 | 15-20 | 40-70 |
| 18 ga (0.048") | 0.030" | 17-18 | 180-250 | 20-25 | 50-90 |
| 16 ga (0.060") | 0.030" | 17-19 | 200-300 | 20-25 | 60-110 |
| 14 ga (0.075") | 0.030" | 18-20 | 250-350 | 25-30 | 80-130 |
| 1/8" (0.125") | 0.030" | 19-22 | 300-400 | 25-30 | 100-160 |
| 3/16" (0.188") | 0.035" | 20-24 | 350-450 | 25-35 | 130-200 |
| 1/4" (0.250") | 0.035" | 22-26 | 400-500 | 30-35 | 160-250 |
| 5/16" (0.313") | 0.045" | 24-28 | 300-400 | 30-40 | 200-300 |
| 3/8" (0.375") | 0.045" | 25-30 | 350-450 | 30-40 | 250-350 |
| 1/2" (0.500") | 0.045" | 28-32 | 400-500 | 35-45 | 300-400 |
How to Read This Chart: Example Row
Take the 1/8" (0.125") row. This tells you:
- Wire: 0.030" ER70S-6
- Voltage: Start at 19V, work up to 22V
- Wire speed: 300 IPM is the low end, 400 IPM is the high end
- Gas flow: 25-30 CFH at the regulator
- Amperage: The machine will draw 100-160 amps depending on voltage and wire speed
Set your voltage to 19V and wire speed to 300 IPM. Run a test bead. If the arc sounds smooth and the bead wets flat into the base metal with no spatter, you’re close. If the wire stubs into the puddle, bump voltage up 1V. If the arc sounds harsh and spattery, reduce wire speed by 25 IPM.
Key Variables That Change These Settings
Joint type matters. A butt joint on 1/8" steel needs less heat than a T-joint fillet on the same thickness because fillet welds split heat between two plates. For fillets, bump voltage and wire speed up 10-15% from the chart values.
Position changes everything. Vertical-up and overhead positions need 10-15% less heat than flat or horizontal. Gravity works against you. Too much heat and the puddle sags or drips. Reduce wire speed first, then voltage if needed.
Gas mix affects penetration. These settings assume 75/25 argon/CO2. Straight CO2 gives deeper penetration but more spatter. You can drop voltage 1-2V with straight CO2. Pure argon (for aluminum or stainless with a spool gun) requires different settings entirely.
Wire stick-out (contact tip to work distance) is 3/8" to 1/2" for most situations. Too much stick-out drops amperage and produces a cold, ropey bead. Too little stick-out overheats the contact tip and causes burnback.
Notes and Limitations
These settings apply to short-circuit transfer mode, which is standard for material under 3/16". For 1/4" and thicker steel, many welders switch to spray transfer with higher voltage, higher wire speed, and 90/10 argon/CO2 or pure argon gas. Spray transfer requires settings outside the ranges shown here.
Multi-pass welds on thick material (3/8"+) need a root pass at the low end of the range, then fill passes at the high end. Let each pass cool to 400 degrees F (205 degrees C) or below before running the next one on mild steel.
Flux-cored wire (FCAW) uses different voltage and wire speed settings. Do not use this chart for flux-cored. See our separate flux-cored welding settings reference.