Are there any charts showing filler rod thickness vs base metal thickness for steel and aluminum? I'm looking at buying a bunch of filler rod for welding mild/stainless/ aluminum and was wondering what diameters I should order.

Regards,
Justin

 

http://www.millerwelds.com/edu...r.php

 

I dont know of any chart,
but from experience and feel while welding..

<U>Aluminum </U>
1/16 rod for 1/16" thick
3/32 rod for 1/8" thick
(You can use 1/8" rod for 1/8" thick. I did as a beginner.)

<U>Mild Steel </U>
(same filler rod diameters as above)

<U>Stainless </U>
(same filler rod diameters as above)

Basically, go with whatever feels best.
As Im getting better,
I find myself using smaller dia. rods like 1/16 and feeding more.
Sometimes, MIG wire (.045" - .03") for small stuff.
You do get a "cooler" weld if working with the small rods.

 

THere is no set rule really. You'll figure out what works for you and in what positions etc.

you will mostly use 1/16,3/32,1/8 and maybe some smaller stuff like .035-40 if you do some thin stuff.

 

The sizes I have for GTAW is
Mild Steel
1/16"
3/32"
1/8"

Stainless
308
.035"
1/16"
3/32"

309
1/16"

347
.035

Aluminum
4043
1/16"
3/32"
1/8"
3/16"

5356
1/16"
3/32"

Others
Inconel 625 .035"
ERti-5 6AL-4V .035"
SiBr 1/16" and 3/32"

 

I weld my 0.065" SS using 1/16" filler rod, only because I now prefer to weld hot and super fast, so I dont run out of filler 2" into the weld

 

.035" 308L for 1/16" SS 304 tubing for exhaust stuff, with argon back-purge and .035" gap for butt welds. Makes a very nice shiny SS weld at 29 amps on my TIG. Read about it on Burns Stainless web site. 1/16" rod for same job is not as nice. Otherwise as described above.