Welding Wire & Electrode Sizes
Tool Drives & Bit Shanks · 9 specs
Direct Answer
Welding filler metals are standardized under American Welding Society (AWS) and ISO specifications into MIG solid wires (.023", .030", .035", .045" / 0.6–1.2 mm), Stick SMAW electrodes (AWS E6010, E6013, E7018 from 3/32" to 5/32"), and TIG tungsten color-coded alloy classifications.
Source: AWS A5.18 (MIG Solid Wire) / AWS A5.1 (Carbon Steel Electrodes) / AWS A5.12 (Tungsten Electrodes) · Last reviewed Aug 28, 2026
Specs
| Governing Standards | AWS (American Welding Society) / ISO 14341 (GMAW) / ISO 2560 (SMAW) / ISO 6848 (TIG) |
| MIG Wire .023" (0.6 mm) | Current: 30–90 Amps | Sheet metal (24 to 18 gauge), auto body restoration, thin exhaust tubing |
| MIG Wire .030" (0.8 mm) | Current: 40–145 Amps | Universal hobbyist & light fabrication standard (18 gauge to 3/16" plate) |
| MIG Wire .035" (0.9 mm) | Current: 50–180 Amps | Industrial structural fabrication, general repair (16 gauge to 3/8" plate) |
| MIG Wire .045" (1.2 mm) | Current: 120–280 Amps | Heavy structural steel, trailer frames, shipbuilding (1/4"+ plate) |
| Stick E6010 / E6011 (Fast Freeze) | 60,000 psi tensile | Cellulose coating | Deep penetration through rust, mill scale, and dirt |
| Stick E7018 (Low Hydrogen) | 70,000 psi tensile | Iron powder low-hydrogen coating | Code-quality structural building bridges/skyscrapers |
| TIG Tungsten Red (EWTh-2) | 2% Thoriated | DC electrode negative (Steel, Stainless) | Radioactivity concerns in EU |
| TIG Tungsten Gold (EWG) | 1.5% Lanthanated | Universal DC/AC (Steel, Stainless, Aluminum) | Modern non-radioactive replacement |
MIG Solid Wire (AWS ER70S-6) Thickness & Plate Gauge Match
| Wire Diameter (Inches) | Wire Diameter (Metric) | Recommended Current Range | Optimal Material Thickness | Primary Welding Application |
|---|---|---|---|---|
| .023" / .025" | 0.6 mm | 30 to 90 Amps | 24 gauge to 18 gauge (0.6–1.2 mm) | Auto body sheet metal panels, rust patches |
| .030" | 0.8 mm | 40 to 145 Amps | 18 gauge to 3/16" (1.2–4.8 mm) | General light fabrication, roll cages, brackets |
| .035" | 0.9 mm | 50 to 180 Amps | 16 gauge to 3/8" (1.5–9.5 mm) | Universal Industrial Workshop Benchmark |
| .045" | 1.2 mm | 120 to 280 Amps | 1/4" to 1/2"+ (6.4–12.7 mm+) | Heavy equipment repair, trailer frames, bridges |
Decoding the AWS Stick Electrode Numbering (e.g. E7018)
- E: Electrode.
- 70 (First Two Digits): Minimum Tensile Strength in thousands of PSI (70,000 psi).
- 1 (Third Digit): Welding Position capability (1 = All Positions flat, horizontal, vertical-up, overhead; 2 = Flat/Horizontal fillet only).
- 8 (Fourth Digit): Coating type and electrical polarity (8 = Low-hydrogen iron powder coating, DCEP reverse polarity).