Stronger welds, less splatter, and distortion are some of the reasons why anyone would take up pulse MIG welding. But before you can get these results, you will have to decide on the right settings for your pulse welder.
Finding the ideal parameters might be difficult. For this reason, it would help if you worked with a chart and guide that can offer these settings quickly.
Would you like to get the best results from your next pulse MIG project? If yes, you can go through this article and find the ideal settings for the pulse MIG weld. Now let’s get started.
Pulse MIG Settings Chart and Guide
Here is a chart showing various settings for using a pulse welder like the Millermatic 255. Although this chart is well-researched, it would help if you consulted the door chart of your welder.
1. Pulse MIG Settings Chart for Aluminum, DCEP Polarity, Wire Type ER4043 and Argon Shielding Gas
| Wire Size | 18 ga ( Wire Feed Speed) | 14 ga ( Wire Feed Speed) | ⅛ ” ( Wire Feed Speed) | ³/¹⁶” ( Wire Feed Speed) | ¹/⁴” ( Wire Feed Speed) | ³/⁸” ( Wire Feed Speed) | ½ ” ( Wire Feed Speed) |
| 0.035″ | 125 | 235 | 350 | 500 | 600 | 800 | |
| 0.047″ | 75 | 130 | 225 | 300 | 360 | 400 | 450 |
If you are working with a 0.035″ ER4043 aluminum wire with Argon gas, the wire feed speed for 18 ga thickness should be 125. But if the wire measures 0.047″, the wire speed feed should be 75.
2. Pulse MIG Settings Chart for Aluminum, DCEP Polarity, Wire Type ER5356 and Argon Shielding Gas
| Wire Size | 18 ga ( Wire Feed Speed) | 14 ga ( Wire Feed Speed) | ⅛ ” ( Wire Feed Speed) | ³/¹⁶” ( Wire Feed Speed) | ¹/⁴” ( Wire Feed Speed) | ³/⁸” ( Wire Feed Speed) | ½ ” ( Wire Feed Speed) |
| 0.035″ | 150 | 327 | 480 | 600 | 700 | – | – |
| 0.047″ | 85 | 165 | 300 | 375 | 500 | 550 | 600 |
According to this chart, a wire size of 0.035 and 18ga thickness requires a wire feed speed of 150. However, a speed of 85 is ideal for a 0.047 wire with the same thickness.
3. Pulse MIG Settings Chart for Stainless Steel, DCEP Polarity, Stainless Steel 308L Wire type and 65 % Argon, 33 % Helium, and 2% Carbon dioxide Shielding Gas
| Wire Size | 18 ga ( Wire Feed Speed) | 14 ga ( Wire Feed Speed) | ⅛ ” ( Wire Feed Speed) | ³/¹⁶” ( Wire Feed Speed) | ¹/⁴” ( Wire Feed Speed) | ³/⁸” ( Wire Feed Speed) | ½ ” ( Wire Feed Speed) |
| 0.035″ | 100 | 150 | 235 | 300 | 400 | 500 | |
| 0.047″ | – | 90 | 125 | 140 | 175 | 250 | 300 |
On this chart, a wire size of 0.035″ with 14ga thickness goes with a wire speed of 150. But if the wire measures 0.40 ( with the same thickness), then the speed should be 90.
4. Pulse MIG Settings Chart for Steel, DCEP Polarity, Solid Wire ER70S-6 Wire type, and C10 Shielding Gas
| Wire Size | 18 ga ( Wire Feed Speed) | 14 ga ( Wire Feed Speed) | ⅛ ” ( Wire Feed Speed) | ³/¹⁶” ( Wire Feed Speed) | ¹/⁴” ( Wire Feed Speed) | ³/⁸” ( Wire Feed Speed) | ½ ” ( Wire Feed Speed) |
| 0.035″ | 130 | 215 | 270 | 330 | 435 | 600 | 700 |
| 0.047″ | 125 | 150 | 200 | 250 | 300 | 400 |
If the 0.035 ” steel wire has a ¼” thickness, the welder should be set to 435. But if the same wire has a thickness of ⅜”, then the speed should be left at 330″.
What is the Pulse Setting on a MIG Welder?
The Pulse MIG setting consists of the transfer of filler metal from the wire to the weld pool without both items ( wire and weld pool) touching each other. With this process, you can expect less splatter and stronger welds.
What is the Difference Between MIG and Pulsed MIG?
If you are using pulsed MiG welding, then you will have to use a peak and background amperage. But if you are working with conventional MIG welding, you will have to use a constant amperage.
What is the Advantage of Pulse MIG Welding?
Several benefits come with pulse MIG welding. For instance, this method of welding promises a stronger weld and less splatter. Moreover, it also removes the need to make extra passes over the workpiece.
MIG Settings Calculator
If you don’t have a chart, you can use a MIG settings calculator to find the ideal adjustments for your weld. To get such an item, type ” MIG Settings Calculator” into the Search bar of your search engine. Then click any of the offered sites and follow the on-screen instructions.
What are the 3 Settings on a MIG Welder?
The three settings on a MIG welder include voltage, gas flow rate/ gas type or mixture, and wire feed speed. But as you choose these settings, consider the length and thickness of the wire.
