Welding Parameters Tool
A quick reference tool for MIG, Flux Cored MIG / FCAW, TIG, MMAW/Stick and plasma cutting. Select a process, material, material type, welding position and thickness. The parameters update automatically as you change the options.
Get Welding Parameters
Quick Welding Questions
Can I weld 3mm aluminium with my 185 amp MIG welder?
Yes, but you will need the correct setup. Use 100% Argon gas, ER4043 or ER5356 aluminium wire, and a suitable aluminium liner for the gun lead if you do not have a spool gun or push-pull gun. Keep the lead as straight as possible to reduce birdnesting. Clean both surfaces with a dedicated stainless steel wire brush before welding.
When should I use Flux Cored MIG / FCAW?
Flux cored wire is useful for outdoor work, dirty steel, heavier sections and jobs where gas shielding is not practical. Gasless flux core usually creates more smoke and spatter than solid wire MIG, but it can be handy for site work and farm repairs.
Is flux core good for exhaust pipe?
It can work, but it is not ideal on very thin exhaust tube because it runs hotter and can burn through easily. Thin exhaust work is usually easier with TIG or low-heat MIG using solid wire and shielding gas.
What changes when welding vertical up or overhead?
Vertical up and overhead welding normally need tighter control, shorter arc length, smaller weld pools and often slightly reduced heat compared with flat welding. Travel angle and technique become much more important.
Can I weld galvanised steel?
Yes, but galvanised coatings create harmful fumes and contamination. Grind the coating away from the weld area where possible, ensure excellent ventilation and use suitable respiratory protection. Avoid breathing zinc fumes.
Troubleshooting Notes
Porosity
Check gas flow, leaks, wind, contamination, damp consumables and surface prep.
Lack of Fusion
Increase heat input, slow travel speed, improve joint prep and check torch angle.
Burn Through
Reduce amperage/voltage, increase travel speed, use backing or reduce gap. Be especially careful with exhaust pipe and thin sheet.
Heavy Spatter
Check voltage, wire feed, stick-out, polarity, gas choice and contact tip condition. Flux core will usually spatter more than solid wire MIG.
Workshop Safety
- Wear proper welding helmet, gloves, clothing and eye protection.
- Use suitable ventilation, especially on galvanised, painted, coated or unknown materials.
- Secure gas cylinders correctly and keep flammables away from welding and cutting areas.
- Follow workplace procedures, manufacturer instructions and relevant safety standards.
- Do not use these settings for critical structural, pressure vessel or coded work without qualified procedures.
Disclaimer
Aaron's Welding Parameters provides general welding guidance and starting points only. Welding settings vary by machine, consumables, technique, joint design, position and work conditions. Always test settings before production work and follow professional safety requirements.
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Contact
For corrections, feedback or welding topic suggestions, add a contact email here before public launch.