Hobby MIG Welding Calculator
This calculator is intended as a guide to initial power and wire feed settings for people new to welding. The settings in the calculator suit me (a DIY welder).
Take it as a starting point but use other pages on this tutorial (such as the page about setting wire speed and the one about finding the right voltage setting) and play around on some scrap to find settings that suit your own welding speed and technique.
Estimated thickness for each power setting - example for Portamig181
The table estimates the range of steel that might comfortably be welded for each power setting.
Power setting | Steel thickness |
|---|---|
1 | 0.8 to 1.0 |
2 | 1.0 to 1.2 |
3 | 1.3 to 1.6 |
4 | 1.7 to 2.1 |
5 | 2.1 to 2.6 |
6 | 2.6 to 3.3 |
7 | 3.2 to 4.0 |
8 | 3.9 to 4.9 |
9 | 4.6 to 5.8 |
Notes about the estimates
- This calculator may be inaccurate at thicknesses above 5mm
- The estimates assume butt welding two pieces of sheet together, having penetration all the way through the sheet, and continuous welding.
- Speed of welding and differences in technique will affect choice of power setting. My own torch travel speed is relatively low (hobby welder speed). Power can be increased if the speed of torch travel is increased.
- Thickness estimates could be increased by about 50% if the steel were prepared with V edges.
- Thinner metal can be welded using an on/off stitching technique.
How to use the calculator
These figures can be found from manufacturer or retailers' specs.
For example a Sip Migmate 130 has a minimum output current of 25 amps, maximum of 130 amps, and has 6 power settings.
Use the links below to fill in the form with data for the following welders:
The estimates will appear in a table (above) after you have filled in the form.
Wire speed Reference
The 0.6mm wire size figures have been tested to 2mm and the figures are extrapolated. The 0.8mm figures have been extrapolated from the 0.6mm results so will be less reliable, but they are at least a starting point. Where the figures are against a grey background the wire size isn't really suitable for the material thickness.
The markings on welder wire feed controls do not represent speed in metres per minute. Measure the speed using a stopwatch and tape measure. It might be useful to mark positions around the wire feed knob for future use.
Steel Thickness (mm) |
Wire Speed (metres per minute) |
|
|---|---|---|
|
0.6mm wire |
0.8mm wire |
0.8 |
2.5 |
1.6 |
1.0 |
3 |
1.9 |
1.2 |
3.6 |
2.2 |
1.5 |
4.3 |
2.6 |
2.0 |
5.6 |
3.5 |
3.0 |
7.9 |
4.9 |
4.0 |
9.8 |
6.1 |
5.0 |
12.5 |
7.7 |
How it was done
The estimates are based on experimental results from a Clarke 90EN, a Clarke 155T, and a Portamig 181, and gaps have been filled in by extrapolation. The method is un-scientific, but the results seem quite accurate for my own welding technique and at the very least should be good for a starting point.
The settings are only intended as a starting point. The wire speed and power settings pages should help fine tune the settings for your welder and welding technique.
Feedback
Do post on the forum with any feedback or problems you may have with the calculator or my suggested settings.