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PWS ENGINEERING TOOLS

Wire-Feed Welding Settings

MIG / MAG, self-shielded flux-core and structural dual-shield references. Get amperage, voltage, wire-feed speed, polarity and technique guidance. Enter what you know; optional details can stay blank. Unknown choices use clearly labelled examples.

1. Metal and joint

Metal Thickness of thinner piece Tube/box section: enter wall thickness, not outside size. Thickness unit 1/8 in = 0.125. Blank always uses the 1/8 in example. Joint

2. Wire and shielding

Wire process Solid + active gas is MAG; solid + inert gas is MIG. Flux-core is FCAW, even on a MIG-capable machine. Reference wire product Use the actual spool if listed. Another brand/classification may have different settings. If absent, enter its matching chart below. Welding position Position alone does not define penetration, pass size or suitability. Use the required WPS for structural work. Wire diameter Match the actual wire. 0.045 in is 1.14 mm, not 1.2 mm. Reference sizes are examples. Shielding gas

Machine and preparation — optional

Machine mode Maximum voltage (V) Maximum wire-feed speed (m/min) Maximum machine current (A) Check duty cycle too. Maximum output is not continuous output. Work location Metal surface Job / machine reference

I have my machine / wire chart — optional

Enter values only from a chart or procedure that matches your actual setup. These appear separately as YOUR values. Leaving them blank does not stop the built-in reference tool. They are useful for a machine-specific pulse program or a setup outside the included charts.

Chart amperage (A) Chart voltage (V) Chart wire-feed speed (m/min) Convert in/min to m/min by multiplying by 0.0254. Chart gas flow (L/min) Convert CFH to L/min by multiplying by 0.472.

Linked wire point and measurements — optional

Use a suitable target from your matching chart or WPS. This links voltage/current to wire speed within the named wire curve. It does not create a qualified joint recipe.

Target wire-feed speed Target / displayed speed unit Measured welding current (A) Measured arc voltage (V) Measured tip-to-work distance (mm) Hand travel speed (mm/min) Used with your measured or chart amps/volts to calculate arc energy.

Check actual wire-feed speed — optional

Use the machine’s cold-feed/inch function with welding output OFF, following its manual. Measure wire fed during a timed test. Keep hands clear of moving wire; do not fire an arc for this measurement. The correction applies near the tested speed. The target is your entered chart wire speed, if provided; otherwise it uses one selected linked point. A range is not averaged into a recommended setting.

Displayed speed during test Uses the speed unit chosen above. Wire length fed (mm) Test duration (seconds)

Your welding reference

Enter what you know, check coverage, then calculate.

What do I set on the welder?

Standard CV wire welding: set voltage and wire-feed speed. The displayed amperage is an estimated resulting current, usually not an independent amperage knob.

Polarity: follow the actual wire label. Solid wire and included dual-shield products use torch-positive; NR-211-MP uses torch-negative.

Gas flow: set the flowmeter while gas flows. L/min and CFH measure the same flow; 1 CFH ≈ 0.472 L/min. Self-shielded wire needs no external gas.

Structural dual shield: intended for structural fabrication references. Confirm the approved WPS, wire classification, gas, progression, preheat/interpass limits and inspection. The app cannot determine those requirements from thickness alone.

Range versus recipe: a wire operating range is not a thickness-specific joint setting. Use a suitable published point and test matching scrap.

Prepare, test, then adjust

Confirm the actual wire, gas, filler compatibility and product-specific polarity.
Use clean matching scrap with the same joint and thickness.
Compare the figures with the machine/wire chart and duty cycle.
Adjust one setting at a time and check fusion and penetration.

Quick troubleshooting

Wire stubbing: check feeding, contact tip and voltage/wire-speed balance.

Burn-through: check gap, heat input and hand travel. Do not treat a lower current as proof of a sound joint.

Porosity: check leaks, drafts, gas supply and contamination.

Bead sits on top: check preparation and fusion. Appearance alone does not prove weld strength.

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PWS Mig Welding App