Welding Tips and Tricks

I am looking for some suggested settings for using .025 solid wire to weld 20, 18, and 16 gauge metal. The calculator that Jody posted is inaccurate for thin metals. I do not have a chart inside the welder because I have a Miller D52-D dual wire feeder and an XMT 304 CC/CV power supply. Looking for actual settings that people have used with success. Thanks.

bilt2spd wrote:I am looking for some suggested settings for using .025 solid wire to weld 20, 18, and 16 gauge metal. The calculator that Jody posted is inaccurate for thin metals. I do not have a chart inside the welder because I have a Miller D52-D dual wire feeder and an XMT 304 CC/CV power supply. Looking for actual settings that people have used with success. Thanks.

Joint configuration/position?

Mostly 1" square tubing, t and butt joints, all positions, and welding sheet metal to it.

For T- and butt-joints using 0.023" ER70S-6 on 16ga, I have previously used 270 IPM/17.5V ±15% depending on a couple other factors. I don't do much below that thickness

That's what I was looking for, a good starting point. Thank you so much.

I'm assuming you're using 75/25 not Co2 right? I might add that you often need to increase your travel speed signifcantly on thinner metal, and it really helps to do short runs, because you'll often blow suddenly blow through 4-5 inches into your weld even though you had the same stickout and travel speed because the surrounding metal heated up.

Which gas are you using? That would be helpful to know. Also I agree with the Oscar's starting point suggestion. You can try that and tweak a bit from there. Which machine do you have and do you have fine tuning settings available?

good point about the gas.

high argon mix is better for thin stuff.
90/10 or 93/5/2.