TOOLS / WELDING

MIG starting settings calculator

Get a sane starting voltage and wire-feed speed for a MIG (GMAW) setup on a new thickness, instead of guessing and burning through — then prove it with a test weld.

Starting voltage18–20 V
Starting wire-feed speed5–7 m/min

Starting shielding gas: Argon/CO₂ mix (typical starting gas — confirm with the filler maker). Run a test weld and adjust to the bead; travel speed, stick-out and joint type also affect the result.

STARTING POINT ONLY — this is not a welding procedure specification (WPS). Settings do not prove weld quality. Verify with the machine and filler makers' tables, qualify the procedure, and inspect structural welds as specified.

Formula

There is no single standard formula for MIG settings: they are empirical. This tool uses an indicative starting table by material thickness band and wire diameter, with a small voltage shift for stainless steel (−1 V) and aluminium (+2 V) against mild steel. Always run a test weld and adjust to the bead.

Standard / source

Filler-maker and machine-maker (for example Miller / Lincoln) parameter tables. Those tables vary by maker, machine, gas and joint, so the ranges here are starting points only — check the table for your own machine and filler before production welding.

Worked example

Mild steel, 6 mm thick, 1.0 mm wire: the 3–6 mm thickness band gives a starting range of 18–20 V and 5–7 m/min wire-feed speed. These are the calculator's default inputs, so it shows 18–20 V and 5–7 m/min on load.

Safety note

STARTING POINT ONLY — this is not a welding procedure specification (WPS) and must never be presented as one. Settings do not prove weld quality: the governing WPS, welder qualification, joint preparation and inspection govern, especially for structural welds.