Welding Calculator

MIG (Metal Inert Gas / GMAW — Gas Metal Arc Welding) uses a continuously fed wire electrode with shielding gas. TIG (Tungsten Inert Gas / GTAW — Gas Tungsten Arc Welding) uses a non-consumable tungsten electrode with a separate filler rod added manually. STICK (SMAW — Shielded Metal Arc Welding) uses a consumable flux-coated electrode (rod) that creates its own shielding gas, so no external gas supply is needed.

Shielding gas choice depends on the material's reactivity. Aluminum uses 100% pure argon because it provides inert protection without reacting with the aluminum. Mild steel MIG uses CO2 or an Ar+CO2 mix because CO2 provides deep penetration and is cost-effective. Stainless steel MIG uses Ar+2%CO2 to balance penetration with oxidation control — more CO2 would cause excessive oxidation of the chromium in the stainless steel.

For MIG welding mild steel, the recommended amperage range is 130–200 A with a voltage of 18–24 V, using 0.8–1.0 mm wire at a feed rate of 5–8 m/min. These are starting reference values for typical material thicknesses. Thinner material requires lower amperage; thicker material requires more. Always run test welds on scrap pieces before welding the actual workpiece.

Aluminum has high thermal conductivity — it dissipates heat very quickly. This means you need higher amperage (150–230 A) to maintain sufficient heat at the weld puddle. Aluminum also melts at a lower temperature than steel, but the rapid heat dissipation compensates, requiring more input energy. Aluminum MIG welding also typically uses larger wire (1.0–1.2 mm) and 100% argon shielding.

Travel speed is how fast the welding torch moves along the joint, measured in cm/min. It directly affects the bead width, penetration depth, and heat input. Moving too slowly causes excessive heat buildup, wide beads, and possible burn-through. Moving too fast creates narrow, high-crown beads with poor fusion. The travel speeds in this tool (e.g., 30–50 cm/min for mild steel MIG) are typical starting references for flat position welding.

TIG welding produces the highest quality, cleanest welds with superior aesthetic appearance and is preferred for thin materials, precision work, visible seams, and corrosion-sensitive applications. MIG is faster and easier to learn, making it better for production welding, thicker materials, and situations where speed matters more than cosmetics. TIG requires more skill and is typically slower; MIG is more beginner-friendly.

For TIG welding, gas flow rates of 8–12 L/min are typical for steel and stainless steel applications, and 12–18 L/min for aluminum. Higher flow is needed for aluminum because it is more reactive and welded at higher amperages that disturb the gas envelope. Too low a flow rate causes atmospheric contamination (porosity, oxidation); too high wastes gas and can create turbulence that draws in air.

These are reference starting ranges based on standard industry practice. Actual optimal settings depend on your specific welder model, material thickness, joint configuration (butt, fillet, overlap), welding position (flat, vertical, overhead), and ambient conditions. Use these values as a starting point, then fine-tune on test pieces. For critical structural or pressure welds, follow a Welding Procedure Specification (WPS) rather than general reference data.