MIG Welding Parameter Charts

🛠️ MIG Welding Parameter Charts — ARCPEX Quick Reference 2026

The most common question from welders at every level: "What settings should I use?" These charts give you tested starting-point parameters for the most common materials and thicknesses — dial in from there.

📌 About These Charts

All parameters tested on ARCPEX MIG200 & MIG200 DP LCD welders | March 2026 lab data | Always test on scrap material first — results vary by joint fit-up, travel speed, and ambient conditions. Download full resource guide →

🔩 Chart 1: Mild Steel (MIG)

Gas: C25 (75% Argon / 25% CO₂) | Flow rate: 15–20 CFH

Thickness Voltage Wire Speed Wire Size Amperage
0.8mm (24 ga) 14–15V 3.0 m/min 0.6mm 40–60A
1.5mm (16 ga) 17–18V 4.0 m/min 0.8mm 80–100A
2.0mm (14 ga) 18–20V 4.8 m/min 0.8mm 100–120A
3.0mm (1/8") 20–22V 5.5 m/min 0.9mm 130–150A
4.5mm (3/16") 22–24V 6.2 m/min 0.9mm 150–170A
6.0mm (1/4") 24–26V 7.0 m/min 0.9mm 170–200A

✨ Chart 2: Aluminum (MIG / Spool Gun)

Gas: 100% Argon | Flow rate: 20–30 CFH | Use push technique only

Thickness Voltage Wire Speed Wire Size Amperage
1.2mm (RV panel) 15–16V 3.5 m/min 0.8mm 60–80A
2.0mm 18–19V 5.0 m/min 0.8mm 90–110A
3.0mm 19–21V 5.8 m/min 1.0mm 120–140A
4.0mm 21–23V 6.5 m/min 1.0mm 140–160A
6.0mm 23–25V 7.5 m/min 1.2mm 160–190A

🔘 Chart 3: Stainless Steel (MIG)

Gas: 98% Argon + 2% CO₂ | Flow rate: 15–18 CFH

Thickness Voltage Wire Speed Wire Size Amperage
1.5mm 16–18V 4.0 m/min 0.8mm 80–100A
3.0mm 19–21V 5.0 m/min 0.9mm 120–140A
4.5mm 21–23V 6.0 m/min 0.9mm 150–170A

🏠 Chart 4: Galvanized Steel

Gas: C25 | Flow rate: 18–22 CFH | ⚠️ Ensure adequate ventilation — zinc fumes are hazardous

Thickness Voltage Wire Speed Wire Size Amperage
1.5mm 17–19V 4.5 m/min 0.8mm 90–110A
3.0mm 20–22V 5.5 m/min 0.9mm 130–150A

🔧 Chart 5: Flux Core (No Gas / FCAW)

Gas: None required | Ideal for outdoor use and windy conditions

Thickness Voltage Wire Speed Wire Size Amperage
2.0mm 17–19V 3.8 m/min 0.9mm FC 90–110A
3.0mm 19–21V 4.5 m/min 0.9mm FC 120–140A
4.5mm 21–23V 5.2 m/min 0.9mm FC 150–170A
6.0mm 22–25V 6.0 m/min 1.2mm FC 170–200A

🛡️ Shielding Gas Quick Reference

Material Recommended Gas Flow Rate (CFH) Notes
Mild Steel C25 (75%Ar/25%CO₂) 15–20 Best all-around for steel
Aluminum 100% Argon 20–30 Higher flow for aluminum oxidation prevention
Stainless Steel 98%Ar + 2%CO₂ 15–18 Minimizes oxidation on SS
Galvanized C25 18–22 ⚠️ Ventilate — zinc fumes hazardous
Flux Core None — Self-shielding — ideal outdoors

⚠️ Important Notes

  • These are starting-point settings — always test on scrap material first
  • Travel speed, joint fit-up, and wire stick-out all affect final results
  • Preheat thick materials (>6mm) for better penetration and reduced cracking
  • Clean base metal thoroughly — rust, paint, and oil cause porosity
  • ARCPEX MIG200 synergic mode auto-adjusts voltage + wire speed together

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📋 Cite This Resource

ARCPEX. (2026). MIG Welding Parameter Charts — Quick Reference Guide. Retrieved from https://www.arcpexweld.com/pages/parameter-charts

Data source: ARCPEX 2026 Lab Test Data | Last Updated: March 2026 | Media inquiries: press@arcpexweld.com