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How To Select The Correct Diameter for ER70S-6 MIG Welding Wire?

Views: 0     Author: Site Editor     Publish Time: 2025-11-10      Origin: Site

ER70S-6 is the most common and versatile choice for MIG (GMAW) welding of mild steel. But selecting the right diameter is crucial for achieving strong, clean welds and maximizing productivity.

ER70S-6 1.0mm copper coated welding wire

Your choice should be a strategic balance of four key factors:
1. Material Thickness (The Primary Factor): Match the wire diameter to your metal's thickness.
2. Amperage Range of Your Welding Machine: Your machine's power is a key limit. Smaller 110V/140A machines work best with 0.8mm or 0.9mm wire, while industrial 220V+/250A+ machines can effectively run 1.0mm and 1.2mm.
3. Welding Position: For out-of-position welds (vertical, overhead), a smaller diameter like 0.8mm or 0.9mm offers better arc control and puddle management. Larger diameters (1.2mm) are best for high-deposition flat and horizontal fillet welds.

4. Deposition Rate and Productivity: For high-volume, high-speed welding on thick materials in the flat position, larger diameters (1.0mm, 1.2mm) significantly increase your metal deposition rate and overall productivity.


For a detailed reference, please check our following specification sheet.

Wire Diameter Best For Material Thickness Key Characteristics & Typical Use
0.8 mm Thin Sheet Metal (0.6 mm - 3 mm) Excellent for out-of-position welds (vertical, overhead). Low heat input prevents burn-through. Ideal for auto body, exhaust, and light-gauge fabrication.
0.9 mm General Purpose (1.5 mm - 8 mm) The most versatile and popular size.A great balance between deposition rate and control. Suitable for all positions with proper technique.
1.0 mm Medium Duty (3 mm - 10 mm) Good for heavier fabrication where 0.9mm is at its limit. Higher deposition than 0.9mm. Best for flat and horizontal fillets.
1.2 mm Heavy Plate & Structural (5 mm and above) High deposition rate for productive welding on thick sections. Requires a powerful welder (250A+). Primarily for flat and horizontal positions.
1.6 mm Very Heavy Plate & Sub-Arc (10 mm and above) Used with high-current processes, often with automated equipment. Not for general manual welding. Requires a very powerful machine (300A+).



We specialize in providing high-quality welding solutions tailored to your specific needs.

For expert advice and premium welding wires, visit our website: www.szewelding.com

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