Do I Need .025" Wire?

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Maybe this is a dumb question, but I will ask anyway. I MIG a lot, and just about everything I weld runs from 11 gauge to 3/8". I used .030" wire for nearly everything for a long time, but when I started working on heavier things occasionally, I got .035", and it worked well.The question is this: is there any purpose in having .025" wire around a home shop? Is it worth buying a big roll just to keep on hand? I see people saying they use .030" for car bodies, and they're pretty thin, so I kind of wonder how often the skinny stuff would be needed.I was socially distant before it was cool."A man who can't handle tools is not a man. You're disgusting." -- Willy Loman
Reply:Perhaps if you weld a lot of very thin steel, like 18ga or 20ga or thinner, it might be beneficial Sent from my SM-G973U using Tapatalk

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Reply:Very thin steel, (20 gauge) I prefer TIG. In any case, thin steel needs a lot of manipulation to negate the distortion. I spent a significant sum trying to buy equipment wouldn't birdnest .023", without success.I've not in 12 years Millermatic 252 managed to run .023" wire. 16 gauge, 1" square tube works well on .030" wire.An optimist is usually wrong, and when the unexpected happens is unprepared. A pessimist is usually right, when wrong, is delighted, and well prepared.
Reply:I agree with MetalMan.It is alot harder to weld light gauge with 0.035" wire. I did almost all my welding with 0.052 fluxcore since 1980. It was no fun welding  light gauge.  Today I use .0030 fluxcore.  But do get work that is light gauge you do need 0.023. But if you are welding 22 to 18 gauge it will make your life easier. Dave

Originally Posted by Guy Caballero

Maybe this is a dumb question, but I will ask anyway. I MIG a lot, and just about everything I weld runs from 11 gauge to 3/8". I used .030" wire for nearly everything for a long time, but when I started working on heavier things occasionally, I got .035", and it worked well.The question is this: is there any purpose in having .025" wire around a home shop? Is it worth buying a big roll just to keep on hand? I see people saying they use .030" for car bodies, and they're pretty thin, so I kind of wonder how often the skinny stuff would be needed.
Reply:

Originally Posted by Guy Caballero

Maybe this is a dumb question, but I will ask anyway. I MIG a lot, and just about everything I weld runs from 11 gauge to 3/8". I used .030" wire for nearly everything for a long time, but when I started working on heavier things occasionally, I got .035", and it worked well.The question is this: is there any purpose in having .025" wire around a home shop? Is it worth buying a big roll just to keep on hand? I see people saying they use .030" for car bodies, and they're pretty thin, so I kind of wonder how often the skinny stuff would be needed.
Reply:“You can probably weld it with 030.”  In a pinch.  If more than a pinch, like a full hand grab, then it might be worth changing the wire to 025 and tip.  Depending on your liner size,  you might need to change that, too. I used it for a while.  It really limit your output current, so it does not “in a pinch” weld heavier stuff well.  030, has good range for what you described.
Reply:I would suggest buying a 2 pound roll and some gun tips, and giving it a try.  A 2 pound roll of ER70S-6 is less than $10(?).  Maybe the same for some tips?So for about $20 you could give it a try.  use the full role, and it will be clear if it is right for you or not.Depending on your machine, I would even give it a try with .030 rollers - just to try.Geoff
Reply:I keep .023 on my SP135 all the time. I gets used for anything up to 1/8”, anything thicker gets TIGd or the 252.
Reply:Some mig machines won't drive .025" wire well. If it does it could be a nice size in your arsenal. When I have to do thin sheet I still use .030" wire in my  little lincoln as it hates smaller wire. But I use ESAB/Allstate Easygrind wire. It burns so smooth and is easy to dress. I just need to really turn down the volts. .025" stainless? Forget about it. I would rather tig it.Weld like a "WELDOR", not a wel-"DERR"

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Reply:I keep it around along with a Tweco 150 amp gun. The gun comes in handy because of the smaller barrel.Millermatic 255 Dynasty 280 DX TIGRunnerReady Welder IHypertherm 30XP
Reply:

Originally Posted by shovelon

Some mig machines won't drive .025" wire well.
Reply:I see a lot of miss information in this thread in the form of so-called advice.  You don't need a special liner for a smaller wire.  Good luck running .023 or .025 wire with a .030 roller LMAO. To the OP,If you are welding rocker panels/1/4 panels etc. then yes .023 / .025 is very helpfulEspecially with small plug welds in sheet metal. So my advice is do not buy a huge roll just to have it on handIf you are doing that type of work then go down and grab a little small rollJust make sure that you have the appropriate roller on your machine.  Sent from my iPhone using Tapatalk ProMiller 211Hypertherm PM 451961 Lincoln Idealarc 250HTP 221  True Wisdom only comes from Pain.
Reply:John T, I suspect you are calling me out on the suggestion to try using .030" rollers with .023" or .025" wire.  I was sharing what I would try.  I am a believer in trying to do something rather than running scared.  So I tried it.  Well sort of.  I did not have any .023" or .025 wire, but I did want to get an idea if it was plausible.  I did have roll of .035" ER70S-6, and put it in my Millermatic 255.  I have .045" rollers for steel, and .047" U groove rollers for aluminum.  So I tried them both.  The wire fed all 25 feet of the Aluma-pro push pull gun whip.  It fed fine through the gun.  I have to believe it would feed fine in a normal length whip. Yes, I turned in the tension knob a little more than I normally would, but the rollers were not touching each other, they were on the wire.  So in this test, I ran wire .010" and .012" smaller than the diameter called out on the roller, without issue.  The OP is looking to run wire .005" under.Maybe other machines are more sensitive?  I don't know.  I do know that it did work well enough for a test on my machine.Geoff
Reply:

Originally Posted by ToolFanGeoff

John T, I suspect you are calling me out on the suggestion to try using .030" rollers with .023" or .025" wire.  I was sharing what I would try.  I am a believer in trying to do something rather than running scared.  So I tried it.  Well sort of.  I did not have any .023" or .025 wire, but I did want to get an idea if it was plausible.  I did have roll of .035" ER70S-6, and put it in my Millermatic 255.  I have .045" rollers for steel, and .047" U groove rollers for aluminum.  So I tried them both.  The wire fed all 25 feet of the Aluma-pro push pull gun whip.  It fed fine through the gun.  I have to believe it would feed fine in a normal length whip. Yes, I turned in the tension knob a little more than I normally would, but the rollers were not touching each other, they were on the wire.  So in this test, I ran wire .010" and .012" smaller than the diameter called out on the roller, without issue.  The OP is looking to run wire .005" under.Maybe other machines are more sensitive?  I don't know.  I do know that it did work well enough for a test on my machine.Geoff