Welding Amperage Calculator

Inputs

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Process family for starting amperage ranges. Final settings depend on wire/electrode, gas, polarity and procedure.
Material adjustment for the starting chart. Verify exact alloy and filler recommendations before production work.
Base metal thickness. Use the controlling thickness at the joint.
in
Optional shop trim for position, joint fit-up, polarity, wire class, travel speed and machine behavior.
%

Results

Default result
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Recommended current (I)
125 A
Pass

Interpolated starting current; tune from procedure, manufacturer and weld test results.

Also computed

Low end (I_min) 105 A

High end (I_max) 145 A

Voltage starting point (V) 18 V

Voltage is a rough starting point, not a constant-current or WPS requirement.

Wire / electrode / tungsten (d) 0.03 in

Suggested wire diameter.

Single-pass thickness guide 0.25 in

Estimated passes Pass 1

Method notes 4 notes
  • MIG/GMAW mild steel starting range from thickness and the 100% trim factor.
  • Non-stick ranges are interpolated by thickness; wire class, shielding gas, transfer mode, polarity, stickout and machine mode can shift the final range.
  • The thickness is within the simple single-pass guide for this process family.
  • Starting amperage is not weld acceptance. WPS/PQR, filler metal, preheat, interpass temperature, inspection and project code requirements still control production welding.

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