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Old 03-26-2009, 11:41 AM
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Default MIG welding - .023 versus .025

In doing some research about MIG welding sheet metal, I've noticed some folks recommend using .023 wire for vehicle applications of 16g - 20g sheet. I'm trying to understand the differences between .023 and .025 as it relates to the wire itself, tips, and drive roll.

- Is it Ok to use .025 tips and drive roll with .023 wire?
- My welder has guidelines for using .025 wire with different gauge metals. If I use .023, what adjustments should I make (if any) to voltage and wire speed?
- Is there a noticeable difference for a novice hobby welder when switching between .025 and .023?

tx. I've got a Lincoln Sp180.
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Old 03-26-2009, 11:52 AM
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your best bet is to search the lincoln, hobart and miller tech boards. There is also special low build wire for sheet. I strongly recommend it, and it's available from esab and hobart. General Air did carry it at one time.
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Old 03-26-2009, 06:58 PM
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Thanks - I'll check into that special wire.
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Old 03-26-2009, 07:42 PM
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Quote:
Originally Posted by Beater View Post
your best bet is to search the lincoln, hobart and miller tech boards. There is also special low build wire for sheet. I strongly recommend it, and it's available from esab and hobart. General Air did carry it at one time.
I can tell you that doing body work with .035 is a be-atch
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Old 03-26-2009, 08:45 PM
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if you have an sp 180, that only has a 1~10 dial right for speed? If I recall, you will need to do the math. I think the speed on that esab wire was around 280 to 310 but it's been a few years since I was doing sheet metal sculpture.. I might have that wire left over too. I'll check in the morning. If I don't post up, that means I don't have any more.
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Old 03-27-2009, 12:40 PM
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I have been told it's not an issue to use .023 wire with the .025 tips and one guy suggested reaming out the tips a bit to prevent sticking (a problem I have).
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Old 03-27-2009, 10:18 PM
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I use .023 with .023 tips and it works great for me. I have a roll of .035 flux core and tips I have never used, it was recommended for outdoor work when gas blows away in the wind. I didn't know there was such a thing as .025, when I bought my Miller all that was available was .023 and .035.
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Old 03-29-2009, 09:41 AM
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Mine came with .025 tips, drive roll and MIG wire, so I've got all the parts for that size. I bought some .023 wire by accident, but when I did some e-research, it sounds like this size wire is a good choice for sheet metal work.

I'll give it a shot today and see what happens.
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