Welding Parameters for Common Materials

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Getting into welding as an absolute beginner can be a daunting experience, as there are so many things you need to master. Among other things, setting up and dialing in the machine can take a long time and wear you out until you get everything right.

Luckily, most new welding machines offer auto-set or smart MIG options that automatically set the recommended parameters. However, that’s not always the case.

In case you need to adjust parameters manually, we compiled welding parameters for common materials into a quick-reference chart you can use next time you start a project. This guide includes the most common processes and metals you'll encounter as an everyday welder.

MIG Welding Structural Steel Frame

MIG Welding Structural Steel Frame
Source: https://www.youtube.com/watch?v=LITz7kLo-a4&t

MIG Welding Parameters for Most Common Metals (Mild Steel, Stainless Steel, Aluminum)

MIG welding is one of the most straightforward processes for welding thin- and medium-thickness mild steel, stainless steel, and aluminum. MIG welding settings are influenced by several factors, including material type, material thickness, wire diameter, and shielding gas, which directly impact voltage, wire feed speed, and amperage.

The charts below provide reference settings for common mild steel, stainless steel, and aluminum applications.

Note: All provided parameters are for reference only. In reality, welding results may vary depending on equipment manufacturer, metal condition, environmental conditions, joint geometry, or WPS (Welding Procedure Specification). Use the provided charts as a head start until you find a sweet spot that suits your style, equipment, and needs.

MIG Welding for Thick Steel
Source: https://www.youtube.com/watch?v=sIgchLDoz9A

MIG Welding Parameters for Mild Steel

Ar/CO2 (75/25%) Shielding Gas MIG Mild Steel Welding
Metal Thickness	Wire Thickness	Voltage	Wire Feed Speed (WFS)	Amperage
24 ga	.024	13.8	138	30
22 ga	.024	14.1	157	40
20 ga	.024	14.7	197	50
20 ga	.030	14.8	94	50
18 ga	.024	16	295	60
	.030	15	98	60
	.035	14.3	87	60
16 ga	.024	17	394	80
	.030	15.8	126	80
	.035	14.6	98	80
14 ga	.024	18	500	120
	.030	16.5	169	90
	.035	15	150	90
	.045	15.5	79	90
1/8"	.030	18	280	130
	.035	17.5	217	130
	.045	15.8	106	130
3/16"	.030	20	382	150
	.035	21	331	170
	.045	17	154	170
1/4"	.030	21.6	461	170
	.035	21.8	390	190
	.045	18.5	189	190
3/8"	.035	23.3	488	200
3/8"	.045	19	217	200

Notice: 100% CO₂ gas MIG welding provides deeper penetration but higher spatter compared to Ar/CO₂ mixtures.

100% CO2 Shielding Gas MIG Mild Steel Welding
Metal Thickness	Wire Thickness	Voltage	Wire Feed Speed (WFS)	Amperage
24 ga	.024	16.2	126	30
22 ga	.024	16.3	138	40
20 ga	.024	16.5	197	50
20 ga	.030	15.3	98	50
18 ga	.024	17.3	295	60
	.030	15.5	110	60
	.035	15	79	60
16 ga	.024	18	394	80
	.030	16	126	80
	.035	15.8	94	80
14 ga	.024	19	512	90
	.030	17	169	90
	.035	17	130	90
	.045	17.5	79	90
1/8"	.030	19.5	299	130
	.035	18.8	217	130
	.045	18.8	106	130
3/16"	.030	22.2	449	165
	.035	21.5	350	170
	.045	19.8	154	170
1/4"	.030	23.2	500	170
	.035	22.2	378	190
	.045	20.6	177	190
3/8"	.035	23.6	437	200
3/8"	.045	22.5	217	200

MIG Welding with 100% CO₂
Source: https://www.youtube.com/watch?v=pTsithkxj8U&t

MIG Welding Parameters for Stainless Steel

Ar/CO2 (98/2%) Shielding Gas Stainless Steel Welding
Metal Thickness	Wire Thickness	Voltage	Wire Feed Speed (WFS)	Amperage
24 ga	.024	15	154	30
22 ga	.024	16.1	197	40
20 ga	.024	16.7	276	50
	.030	16.3	157	57
	.035	15.3	102	50
18 ga	.024	17.3	374	60
	.030	16.8	197	65
	.035	15.8	138	60
16 ga	.024	18	512	80
	.030	17.9	256	80
	.035	16.2	165	80
	.045	14.7	79	80
14 ga	.030	18.2	276	90
	.035	17	197	90
	.045	14.8	91	90
1/8"	.030	21.1	472	120
	.035	19.6	295	120
	.045	16.5	138	130
3/16"	.035	22.8	433	170
3/16"	.045	18.4	205	170
1/4"	.035	24.1	472	190
1/4"	.045	18.6	217	190
3/8"	.035	24.4	512	200
3/8"	.045	19	236	200

Notice: Tri-gas mix offers deeper penetration and lower spatter than Ar/CO₂ (98/2%) in stainless steel MIG welding.

Tri-gas Mix Shielding Gas Stainless Steel Welding
Metal Thickness	Wire Thickness	Voltage	Wire Feed Speed (WFS)	Amperage
24 ga	.024	15.1	157	30
22 ga	.024	16.5	220	40
20 ga	.024	17.2	354	50
	.030	19	177	50
	.035	—	—	—
18 ga	.024	17.6	433	60
	.030	19.2	197	60
	.035	15.5	126	60
16 ga	.024	18	512	80
	.030	19.7	236	80
	.035	16.5	150	80
14 ga	.030	20.2	295	90
	.035	17.3	185	90
	.045	16	91	90
1/8"	.030	21.5	402	130
	.035	21.1	319	130
	.045	18.3	161	130
3/16"	.030	23	512	160
	.035	22.3	390	170
	.045	19.1	197	170
1/4"	.035	22.9	409	190
1/4"	.045	19.8	236	190
3/8"	.035	26	512	200
3/8"	.045	23.6	295	200

MIG Welding Stainless Steel with Tri Mix Gas
Source: https://www.youtube.com/watch?v=Z4WXVidVu-I&t

MIG Welding Parameters for Aluminum

4043 Wire Aluminum MIG
Metal Thickness	Wire Thickness	Voltage	Wire Feed Speed (WFS)	Amperage
18 ga	.035	13	157	60
16 ga	.035	13	228	80
16 ga	.045	13	118	80
14 ga	.035	17.5	315	90
14 ga	.045	15.5	157	90
1/8"	.035	22	354	130
1/8"	.045	20.5	197	130
3/16"	.035	25.5	413	150
3/16"	.045	23.5	276	170
1/4"	.035	26	427	170
1/4"	.045	24.5	315	190
3/8"	.045	26	354	200

Notice: 4043 offers better weldability, while 5356 provides higher strength and better color match after anodizing.

5356 Wire Aluminum MIG
Metal Thickness	Wire Thickness	Voltage	Wire Feed Speed (WFS)	Amperage
18 ga	.035	13	201	50
16 ga	.035	13	264	70
16 ga	.045	13	157	80
14 ga	.035	15.2	315	75
14 ga	.045	13.5	236	90
1/8"	.035	21.2	370	115
1/8"	.045	20.5	315	130
3/16"	.035	22.8	480	135
3/16"	.045	21.7	354	170
1/4"	.035	23	512	145
1/4"	.045	23	394	190
3/8"	.045	23.7	453	200

Welding Aluminum with 5356 Wire
Source: https://www.youtube.com/watch?v=flyUJ5UImc8

Flux-core Welding Parameters

Flux core welding settings are primarily affected by material thickness and wire diameter. Compared to gas-shielded MIG welding, self-shielded flux core typically requires DCEN (Direct Current Electrode Negative) polarity. It also operates within different voltage and wire feed speed ranges.

The chart below provides reference settings for common E71T-GS self-shielded flux core wire.

E71T-GS Flux Core Wire Steel Welding
Metal Thickness	Wire Thickness	Voltage	Wire Feed Speed (WFS)	Amperage
20 ga	.030	13.8	118	50
20 ga	.035	—	—	—
18 ga	.030	14.2	138	60
18 ga	.035	15	98	60
16 ga	.030	15	157	80
16 ga	.035	15.9	142	80
14 ga	.030	16.5	197	90
	.035	16.6	173	90
	.045	15.2	79	90
1/8"	.030	18	315	130
	.035	18	220	130
	.045	17	130	130
3/16"	.030	19	394	170
	.035	18.5	315	170
	.045	18.5	177	170
1/4"	.030	20	472	190
	.035	19.2	378	190
	.045	19	197	190
3/8"	.035	20.5	480	200
3/8"	.045	19.5	209	200

E71T-GS Flux Core Wire Steel Welding
Source: https://www.youtube.com/watch?v=xq4osYMrPtw

TIG Welding Parameters for Most Common Metals

TIG Welding is the most challenging method, but it yields the highest-quality welds. GTAW offers advanced parameters that let you fine-tune your welds and achieve the best results. Let's see the recommended parameters for common metals such as mild steel, stainless steel, and aluminum.

Source: https://www.youtube.com/watch?v=X1OuWvuWDEk&t

TIG Welding Parameters for Mild Steel

100% Argon Shielding Gas TIG Welding Mild Steel
Metal Thickness	Filler Rod Diameter (in)	Tungsten Diameter (in)	Amperage (A)	Gas Flow (cfh)	Cup Size (in)
20 ga	.040-1/16	.040	25-30	20	—
18 ga	.040-1/16	.040	25-35	20	—
1/16"	.040-1/16	1/16	100-140	20	3/8
3/32"	1/16-3/32	1/16	125-200	25	3/8
1/8"	3/32	1/16-3/32	125-200	25	7/16
3/16"	1/8	1/8	150-250	25-30	7/16
1/4"	1/8	1/8	150-250	25-30	1/2
3/8"	1/8	1/8	150-275	25-30	1/2

TIG Welding Carbon Steel
Source: https://www.youtube.com/watch?v=b79fS4kkztY

TIG Welding Parameters for Aluminum

100% Argon Shielding Gas TIG Welding Aluminum
Metal Thickness	Filler Rod Diameter (in)	Tungsten Diameter (in)	Amperage (A)	Gas Flow (cfh)	Cup Size (in)
1/16"	3/32	1/16-3/32	70-100	20-25	3/8
3/32"	1/8-3/32	3/32-1/8	85-115	20-25	3/8
1/8"	1/8-5/32	1/8	110-150	25-30	7/16
3/16"	5/32	5/32	155-180	25-30	7/16
1/4"	3/16-5/32	3/16	190-275	30	1/2
3/8"	3/16-1/4	3/16-1/4	240-370	30-35	1/2

TIG Weld Aluminum with 100% Argon
Source: https://www.youtube.com/watch?v=6DnA6YLhAno&t

Pulse TIG Welding Parameters for Aluminum

Pulse TIG Welding Parameters for Aluminum
Aluminum Thickness	Peak Amps	Background Amps	Frequency	Pulse On Time
Thin aluminum (1/16" and thinner)	~50-100A	~25-40%	~1-5 Hz	40-60%
Medium aluminum (around 1/8")	~100-150A	~30-50%	~2-10 Hz	40-50%
Thick aluminum (1/4" and over)	~150-200+A	~30-50%	~50-100+ Hz	40-50%

TIG Pulse Welding Aluminum
Source: https://www.youtube.com/watch?v=wAxYlczBKPI

TIG Welding Parameters for Stainless Steel

100% Argon Shielding Gas TIG Welding Stainless Steel
Metal Thickness	Filler Rod Diameter (in)	Tungsten Diameter (in)	Amperage (A)	Gas Flow (cfh)	Cup Size (in)
1/16"	1/16	1/16	80-120	20-25	3/8
3/32"	1/16	1/16-3/32	100-160	20-25	3/8
1/8"	1/16	3/32	120-150	25-30	7/16
3/16"	3/32-1/8	1/8	200-275	25-30	7/16
1/4"	1/8	3/16	275-350	30	1/2
3/8"	1/8	3/16-1/4	240-370	30-35	1/2

TIG Welding Stainless Steel
Source: https://www.youtube.com/watch?v=Rl4Wu6XlJes

Other Helpful TIG Welding Parameters

TIG welding is one of the few processes that allows you to control each part of the welding process, from starting current through upslope, peak, and end current. Here is a recommended starting point for each.

Pre flow	0.5 s
Start current (I start)	35 A
Slope up	0
Primary current (I1)	(Depends on metal thickness)
Background current (I2)	10% of I1
Duty cycle	50%
Pulse Hz DC	0.5-1 Hz
Pulse Hz AC	0.5-1 Hz
Slope down	0
End current (I end)	30 A
Post flow	5 s
Idle time	0.5-1 s
AC frequency	85 Hz
AC balance	35%
Mix Hz	2 Hz

Stick Welding Parameters for Most Common Metals

Stick welding is the industry's workhorse, enabling quick, cost-effective repairs. Due to self-shielded electrodes, it works excellently with outdoor projects and repairs, and it is pretty easy to dial in.

The charts below provide reference settings for common stick welding electrodes and base metals.

Stick Welding on Thin Steel
Source: https://www.youtube.com/watch?v=Dybrlx-BTXk

Stick Welding Parameters for Mild Steel

E6010/E6011
Electrode Diameter	Amperage (A)	Metal Thickness
3/32"	40-85	3/32-3/16"
1/8"	75-125	1/8-1/4"
5/32"	110-165	1/4-3/8"
3/16"	140-210	Over 3/8"
7/32"	160-250	Over 3/8"

Key Difference: E6010/E6011 provide deeper penetration and better performance on dirty or rusted steel, while E6013 produces smoother welds with easier arc control.

E6013
Electrode Diameter	Amperage (A)	Metal Thickness
1/16"	20-45	Up to 1/8"
5/64"	35-60	Up to 3/16"
3/32"	40-90	3/32-3/16"
1/8"	80-130	1/8-1/4"
5/32"	105-180	1/4-3/8"
3/16"	150-230	Over 3/8"
7/32"	210-300	Over 3/8"

Welding Pipe With 6013 Rods
Source: https://www.youtube.com/watch?v=C6LSAjcrWSI

E7014
Electrode Diameter	Amperage (A)	Metal Thickness
3/32"	80-125	3/32-3/16"
1/8"	110-165	1/8-1/4"
5/32"	150-210	1/4-3/8"
3/16"	200-275	Over 3/8"
7/32"	255-340	Over 3/8"

Key Difference: E7014 offers a higher deposition rate and easier operation for general welding, while E7018 provides low-hydrogen welds with higher strength and better structural performance.

E7018
Electrode Diameter	Amperage (A)	Metal Thickness
3/32"	65-100	3/32-3/16"
1/8"	110-165	1/8-1/4"
5/32"	150-220	1/4-3/8"
3/16"	200-275	Over 3/8"
7/32"	260-340	Over 3/8"

Stick electrode charts by KingsOfWelding

Stick Welding with 7018 Rods
Source: https://www.youtube.com/watch?v=BrDwOItX1C4

Stick Welding Parameters for Aluminum

In general, welders rarely stick-weld aluminum. The process itself lacks the cleanliness and heat control required for aluminum, so it is often not the preferred method. However, it is possible, and here are the recommended parameters.

E4043 Aluminum Stick Welding
Source: https://www.youtube.com/watch?v=qpWZW77vLus

E4043
Electrode Diameter	Amperage (A)	Metal Thickness
3/32"	50-80	3/32-3/16"
1/8"	80-130	1/8-1/4"
5/32"	100-160	1/4-3/8"

Stick Welding Parameters for Stainless Steel

E308L-16
Electrode Diameter	Amperage Flat (A)	Overhead and Vertical	Metal Thickness
1/16"	10-30	10-30	Up to 1/8"
5/64"	20-50	15-45	Up to 3/16"
3/32"	50-85	45-75	3/32-3/16"
1/8"	70-110	65-105	1/8-1/4"
5/32"	100-150	95-140	1/4-3/8"
3/16"	130-180	/	Over 3/8"
1/4"	160-210	/	Over 3/8"

Note: E308L-16 is a standard stainless steel electrode for 304/304L applications.

E309L-16
Electrode Diameter	Amperage Flat (A)	Overhead and Vertical	Metal Thickness
1/16"	10-30	10-30	Up to 1/8"
5/64"	30-50	25-45	Up to 3/16"
3/32"	50-85	45-75	3/32-3/16"
1/8"	70-115	65-110	1/8-1/4"
5/32"	100-150	90-140	1/4-3/8"
3/16"	140-190	/	Over 3/8"
1/4"	170-220	/	Over 3/8"

Note: E309L-16 is designed for stainless steel to mild steel and transition welding applications.

E316L-16
Electrode Diameter	Amperage (A)	Metal Thickness
5/64"	20-50	Up to 3/16"
3/32"	50-80	3/32-3/16"
1/8"	70-100	1/8-1/4"
5/32"	90-140	1/4-3/8"
3/16"	120-170	Over 3/8"

Note: E316L-16 is designed for corrosion-resistant stainless steel applications in marine and chemical environments.

Stainless Stick Welding with E316L-16
Source: https://www.youtube.com/watch?v=bSdjUo9X6PM

Additional Stick Welding Parameters

Parameter	Setting
Hot Start	30%
Arc Force	30%
Anti-stick	On
VRD	On

Bonus: Pulsed and Dual Pulsed MIG Parameters for Most Common Metals

Welders such as the YesWelder DP200 Dual Pulse MIG Welder offer pulse and dual pulse MIG. These features provide even better heat control, less spatter, and better weld aesthetics with MIG welding. Here are the recommended parameters for use with the pulsed MIG.

Firstess DP200 Multi-Process DualPulse™ MIG Welder

Pulsed MIG Parameters for Steel

Ar/CO2 (90/10%) Pulsed MIG Mild Steel Welding
Metal Thickness	Wire Thickness	Wire Feed Speed (WFS)	Amperage
20 ga	.030	138	50
18 ga	.030	165	69
16 ga	.030	197	80
16 ga	.035	157	80
14 ga	.030	236	90
	.035	189	90
	.045	106	90
1/8"	.030	472	120
	.035	252	120
	.045	138	140
3/16"	.035	299	170
3/16"	.045	165	170
1/4"	.035	335	190
1/4"	.045	197	190
3/8"	.035	429	200
3/8"	.045	217	200

Pulsed MIG Steel Welding
Source: https://www.youtube.com/watch?v=tH4Chdxtsps&t

Pulsed MIG parameters for Stainless Steel

Ar/CO2 (98/2%) Pulsed MIG Stainless Steel Welding
Metal Thickness	Wire Thickness	Wire Feed Speed (WFS)	Amperage
20 ga	.030	177	50
18 ga	.030	197	60
18 ga	.035	114	60
16 ga	.030	276	80
16 ga	.035	150	80
14 ga	.030	316	90
	.035	201	90
	.045	79	90
1/8"	.030	453	120
	.035	291	120
	.045	126	140
3/16"	.035	358	170
3/16"	.045	169	170
1/4"	.035	421	190
1/4"	.045	197	190
3/8"	.035	453	200
3/8"	.045	217	200

MIG Pulse Welding 316 Stainless Steel Pipe
Source: https://www.youtube.com/shorts/f8GbLKQe6y0

Pulsed MIG Parameters for Aluminum

4043 Wire Pulsed Aluminum MIG
Metal Thickness	Wire Thickness	Wire Feed Speed (WFS)	Amperage
18 ga	.035	134	35
16 ga	.035	169	45
16 ga	.045	134	80
14 ga	.035	209	65
14 ga	.045	169	90
1/8"	.035	331	100
1/8"	.045	236	140
3/16"	.035	457	140
3/16"	.045	276	170
1/4"	.035	512	150
1/4"	.045	315	190
3/8"	.045	374	200

Notice: 4043 delivers smoother welds and easier pulse control, while 5356 provides higher strength for structural aluminum applications.

5356 Wire Pulsed Aluminum MIG
Metal Thickness	Wire Thickness	Wire Feed Speed (WFS)	Amperage
18 ga	.035	165	40
16 ga	.035	213	60
16 ga	.045	157	80
14 ga	.035	287	70
14 ga	.045	197	90
1/8"	.035	413	110
1/8"	.045	315	140
3/16"	.035	512	155
3/16"	.045	394	170
1/4"	.045	453	190
3/8"	.045	512	200

🧐 Welding Parameters for Common Materials

1. What are welding parameters?

Welding parameters are the machine settings that control heat, arc behavior, filler metal feed, and weld quality. Common parameters include voltage, amperage, wire feed speed, gas flow, tungsten size, electrode size, and pulse settings.

2. Are welding parameter charts always accurate?

No. Welding parameter charts are starting points, not fixed rules. The final result can change with metal condition, joint fit-up, machine type, shielding gas, welding position, and the welder’s travel speed.

3. Why do voltage and amperage change with metal thickness?

Thicker metal needs more heat to achieve proper fusion. That usually means higher amperage, higher voltage, or both. Thin metal needs lower heat to avoid burn-through and warping.

4. What does wire feed speed mean in MIG welding?

Wire feed speed controls how fast the filler wire enters the weld pool. Higher wire feed speed usually increases amperage and deposition rate. If it is too high or too low, the arc may become unstable.

5. What is the difference between regular MIG and pulsed MIG parameters?

Regular MIG uses a steady arc, while pulsed MIG alternates between higher and lower current levels. Pulsed MIG can help control heat, reduce spatter, and improve bead appearance, especially on aluminum and stainless steel.

6. How should beginners use welding parameter charts?

Beginners should treat the chart as a safe starting point. Set the machine close to the recommended range, run a test bead on scrap metal, check penetration and bead shape, then make small adjustments until the weld looks and performs correctly.