Wire Size & Material Thickness

Question 1

What wire size for thin metals up to 1/8 inch? Think Light-duty applications, thin metals (e.g., sheet metal, auto body work).

Answer 1

.023 or 0.6mm wire

Question 2

What wire size for 24 gauge to 3/16-inch-thick metal? Versatile; good for mild steel, light fabrication, and general-purpose welding.

Answer 2

.030 or 0.8mm wire

Question 3

What wire for 18 gauge to 1/4 inch? More filler, suitable for thicker metals, general fabrication, and structural work.

Answer 3

.035 or 0.9 mm wire

Question 4

What wire for 1/4 inch and thicker? Heavy-duty welding for thick materials, often used in industrial or structural applications.

Answer 4

.045 or 1.2mm wire

Question 5

What wire for 3/8 inch and thicker? High deposition rates, suitable for very thick materials and heavy industrial applications.

Answer 5

.052 or 1.3mm wire

Question 6

What wire for 1/2 inch or greater? Specialized for heavy-duty and high-output applications, like shipbuilding or large structures.

Answer 6

1/16 or 1.6mm wire