OM-285922 Page 55
SECTION 12 − GMAW WELDING (MIG) GUIDELINES
Wire Feeder/
Welding Power Source
Workpiece
Gun
Regulator/
Flowmeter
Gas
Shielding Gas
Work Clamp
12-1. Typical GMAW (MIG) Process Connections
! Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.
GMAW1 2018−12 (GMAW Only) − Ref. 801909-A
. These settings are guidelines only. Material
and wire type, joint design, fitup, position,
shielding gas, etc. affect settings. Test welds to
be sure they comply to specifications.
1 Material Thickness
Material thickness determines weld parameters.
Convert material thickness to amperage (A):
0.001 in. (0.025 mm) = 1 ampere
0.0625 in. (1.59 mm) ÷ 0.001 = 62.5 A
2 Select Wire Size
See table below.
3 Select Wire Feed Speed (Amperage)
Wire feed speed (amperage) controls weld pene-
tration.
See table below.
4 Select Voltage
Voltage controls height and width of weld bead.
Low Voltage: wire stubs into work
High Voltage: arc is unstable (spatter)
Set voltage midway between high and low voltage.
1/16 or
0.0625 in.
2
1
3
12-2. Typical GMAW (MIG) Process Control Settings
4
Wire Size Amperage Range Recommended Wire Feed Speed Wire Feed Speed*
0.023 in. (0.58 mm) 30−90 A 3.5 in. (89 mm) per amp 3.5 x 62.5 A = 219 ipm (5.56 mpm)
0.030 in. (0.76 mm) 40−145 A 2 in. (51 mm) per amp 2 x 62.5 A = 125 ipm (3.19 mpm)
0.035 in. (0.89 mm) 50−180 A 1.6 in. (41 mm) per amp 1.6 x 62.5 A = 100 ipm (2.56 mpm)
*62.5 A based on 1/16 in. (1.6 mm) material thickness. ipm = inches per minute; mpm = meters per minute
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