← Back to Bead BoardWelding amperage chart
This welding amperage chart covers MIG, TIG, and stick. Pick your process, base metal, and thickness to get starting amps, voltage, wire speed, gas flow, and consumable recommendations. Every number is a conservative starting point cross-referenced against Lincoln, Miller, and Hobart data. Run a test bead on scrap before you run production.
Quick answer
1/4 inch mild steel MIG: 180–250 amps, 20–25V, .035 wire at 280–420 IPM, 75/25 gas at 30–40 CFH. Short circuit transfer. Use the selector below for other processes, metals, and thicknesses.
MIG mild steel — short circuit settings
ER70S-6 wire, 75/25 Ar/CO₂ (C25) shielding gas. These are the most common shop thicknesses in short-circuit transfer mode.
Settings assume flat or horizontal position with clean, mill-scale-free material. Reduce amperage 10–15% for vertical up. Increase gas flow 5 CFH in drafty areas.
TIG mild steel — DCEN settings
ER70S-2 filler rod, 100% argon shielding gas, DCEN polarity. 2% lanthanated tungsten (gold band).
Rule of thumb for steel TIG: ~1 amp per 0.001" of thickness. A 1/8" piece (0.125") needs about 125 amps as a starting point.
Stick electrode amperage by rod diameter
Amperage ranges for the six most common stick electrodes. Pick your electrode, find your rod diameter, and start in the middle of the range.
E7018 is the default for structural work. E6010 for root passes and dirty metal. Start in the middle of the range and adjust by 5–10 amps based on position and fit-up.
Full settings by process
The tables above cover mild steel. For stainless, aluminum, spray transfer, and detailed electrode guides, see the full process pages:
Questions welders keep asking
What amps should I use for 1/4 inch steel MIG?
Start at 180 amps and work up to 250. Use .035 wire with C25 gas (75/25 argon/CO2) at 20-25 volts and 280-420 IPM wire speed. If you are burning through, drop 10 amps and slow your travel speed. If the bead is sitting on top with no fusion, bump it up 10-15 amps.
How do I know my voltage is right?
Listen. A smooth, steady crackle (like frying bacon) means you are in the sweet spot. If it sounds like a machine gun with loud pops, voltage is too low for the wire speed. If the arc is lazy and hissy with lots of spatter, voltage is too high. On short-circuit MIG, voltage controls arc length. Dial it in by ear, then fine-tune by looking at the bead profile.
What is the difference between short circuit and spray transfer?
Short circuit is the default mode on most shop MIG machines. The wire touches the puddle 90-200 times per second, creating short circuits that melt the wire into the joint. Low heat, works in all positions, best for thin to medium material. Spray transfer runs above a critical amperage threshold (about 165A for .035 wire) where tiny droplets stream across the arc without touching. Higher heat input, faster deposition, but limited to flat and horizontal positions. You need 90%+ argon shielding gas for spray.
What TIG tungsten size do I need?
Match the tungsten to your amperage range. 1/16" tungsten handles 30-90 amps. 3/32" covers 80-180 amps. 1/8" covers 150-250 amps. If the tungsten is balling up or melting, go up a size. If you cannot start an arc without contaminating the tungsten, go down a size. For steel and stainless, use 2% lanthanated (gold band). For aluminum on AC, ceriated or lanthanated both work.
Which stick rod should I use?
E7018 is the go-to for structural and general fabrication. Low hydrogen, smooth arc, X-ray quality beads. E6010 for root passes on pipe and dirty metal that you cannot grind clean. E6013 for sheet metal and thin stock where you need a soft arc. E7024 for flat production runs where you want maximum deposition. If you only carry two rods, carry E7018 and E6010.
Do these settings work for stainless and aluminum?
The tables on this page show mild steel because it is the most common. Stainless runs about 10-15% less amperage than mild steel at the same thickness, and you need tri-mix gas for MIG or pure argon for TIG. Aluminum needs about 20-25% more amperage for TIG (on AC) and pure argon for both processes. Use the interactive selector at the top of the page to get settings for all three metals.
Why do my actual settings differ from the chart?
Every chart is a starting point, not a prescription. Your actual settings depend on joint fit-up, position, material condition, machine brand, contact tip condition, and a dozen other variables. Start with the chart number, run a test bead on scrap of the same material and thickness, and adjust from there. If the bead looks good and the penetration is right, that is your setting regardless of what any chart says.