Quick Welding Setup Tool
Choose a process, material, and thickness. The tool gives starting-point settings, consumables, gas, prep notes and common problems to watch for.
Welding Parameter Calculator
MIG Welding Guide
MIG is fast and practical for mild steel, stainless and aluminium when the machine, wire feed system, gas and prep suit the material. Aluminium MIG usually needs excellent cleaning, 100% argon, correct wire, and a spool gun or push-pull system for reliable feeding.
Common MIG outputs
Voltage, wire speed, amperage estimate, wire size, wire type, gas type, gas flow, polarity and prep notes.
Common MIG issues
Porosity, lack of fusion, burn-through, birdnesting, undercut, spatter and poor gas coverage.
TIG Welding Guide
TIG gives precise control for stainless, aluminium and thin materials. The calculator provides AC/DC guidance, tungsten size, filler rod suggestions, gas flow and amperage starting points.
MMAW / Stick Welding Guide
Stick welding is tough, portable and useful outdoors. Results depend heavily on electrode type, rod size, polarity, material condition, arc length and operator technique.
Plasma Cutting Guide
Plasma cutting needs suitable amperage, clean dry air, correct consumables, proper earth connection and suitable travel speed. Poor air quality quickly causes bad cuts and short consumable life.
Material Notes
| Material | Important notes |
|---|---|
| Mild Steel | Forgiving, common, suitable for MIG/TIG/Stick. Remove mill scale for cleaner welds. |
| Stainless Steel | Control heat input. Use correct stainless filler, avoid contamination, and clean with dedicated tools. |
| Aluminium | Clean oxide layer with a dedicated stainless brush. Use correct aluminium filler and pure argon shielding gas for most MIG/TIG work. |
| Galvanised Steel | Produces hazardous fumes. Remove coating where safe and use strong ventilation / correct PPE. |
| Cast Iron | Often requires preheat, nickel rods/filler and slow cooling. Treat as repair-specific work. |
Troubleshooting Quick Guide
Porosity
Check gas coverage, leaks, contamination, wind, moisture, paint/oil and excessive gas turbulence.
Lack of Fusion
Increase heat input, slow travel speed, improve joint prep, clean material and check torch angle.
Burn-through
Reduce amps/volts, increase travel speed, use smaller wire/rod or improve backing/support.
Aluminium Birdnesting
Use correct drive rolls, lower tension, short liner path, suitable liner and spool gun/push-pull if needed.
Safety Guide
Welding and cutting can cause electric shock, burns, eye damage, fire, toxic fume exposure, explosion risk and injury from hot metal or compressed gases. Use correct PPE, ventilation, fire controls, cylinder handling and training.
Legal, Privacy & Contact
About
Aaron's Welding Parameters is a practical reference site created to help people find sensible starting points for welding and cutting setup.
Contact
Email: contact@aaronsweldingparameters.com
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Terms
Use this site for general information only. You are responsible for checking settings, safety requirements and suitability for your equipment and job.
Disclaimer
All settings are starting points only and may not suit every machine, material, weld position, joint preparation or job requirement.