The first thing to note is that its spec sheet says explicitly that all diameters under 0.045” can’t weld above 5/16”. So, let’s take a look at Lincoln’s Innershield NR-211MP (AWS – E71T-11), one of the top-rated, standard 0.030” cored wires for all position welding. It also works fine at 120V, but you should use a higher voltage to burn it hot and get the best penetration. This wire will perform best if you use it with 210V input.

Welding thicker than 14 gauge is possible with multiple passes, but only if the wire is designed for it. You can even try 24 gauge, but it can lead to burn-through. It will weld anything between 22 gauge and 14 gauge thick. It’s primarily used for light welding work outdoors or by people who don’t want to bother with the whole MIG shielding gas setup. The 0.030” diameter flux-cored wire is a typical hobbyist-level wire meant for thinner metal. The chemical compounds and manufacturing processes vary between different production plants. But be aware that specific brands can provide different results. I will explain both wires in a general manner. Let’s dig in a little deeper to explore the differences between these two cored wire thicknesses in real-world examples. Material Thickness Range Single Pass (mild steel) It’s difficult to compare real-world products because most of them don’t provide the necessary data. Let’s compare these two diameter flux-cored wires side by side by using some general metrics. 0.035 – Which One Should You Use?+ Side-by-Side Comparison So, you will have to switch polarity between your MIG gun and the ground clamp when changing over to flux-cored wire. Most cored wires are designed to work with direct current electrode negative (DCEN), which is the opposite of solid steel MIG wires. The outer tube of the wire is called the “jacket” or “sheath,” while the mixture inside is called the “flux-core.” Cross section of flux-cored wire The lap joint is somewhat more secure against moisture contamination. The seam can be either a lap or a butt joint. Flux is poured into the cavity, and the seam is tightly rolled closed. In addition, they can be used in all positions or flat/horizontal only.Ĭored wires are typically manufactured by taking a thin steel strip and rolling it in a “U” shape. These wires are available in many different diameters, including 0.030” and 0.035”. This applies only to self-shielded flux-cored wires (FCAW-S), which most people use. That’s why no shielding gas is necessary when using a flux-cored wire. Read more: What is Flux in welding & What is it used for?Įffectively, the two typical weld contaminants (oxygen and nitrogen) transform into protective compounds. These newly formed compounds solidify rapidly on the weld surface and protect the bead from atmospheric contamination. Once exposed to gasses in the atmosphere, deoxidizers form aluminum oxide, aluminum nitride, and magnesium oxide. The deoxidizers found in cored wires are typically aluminum and magnesium. It also collects the impurities in a layer of slag on top of the bead, which is chipped off after the weld cools down. This flux is a compound mixture of alloys and deoxidizers that allow users to weld dirtier metal and it be used in windy conditions.įlux generates shielding gasses when flux-core welding, which protects the molten weld pool from oxygen and nitrogen and stabilizes the arc. It’s like a stick electrode turned inside out. A flux-cored wire is essentially a tube packed with a flux substance in its core.

Stainless steel flux core welding wire