How to pick the right material filler for your welding job


Another thing that makes welding different is if there is a variety of welding rods or wire to choose from depending on your job/projects. All you have to do is be able to answer these simple questions to find the perfect wire.

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When choosing your wire for MIG welding you have 3 main choices. Flux Core Wire, Mild Steel Wire, and Aluminum Wire. 

Which wire you choose to use is really up to you and what you are doing. A rule of thumb is that you typically use stainless steel wire to weld in a shielding gas, which will be all of the wire but the Flux Core wire and if you want to use two wires on one machine, this will be one of them if all you are doing is regular welding on anything you have to go with just the Flux Core wire.

Base Metal

Picking out the right MIG Wire will be of the most importance whenever you decide to MIG weld. There are many different types of wires that all provide different properties when you MIG weld. These wires may range from ER70s-6 wire, which may not be used for all MIG applications, to aluminum drive rolls that may only be used to weld aluminum. There are also a few other types of wire such as stainless steel drive rolls, which are only meant to weld stainless steel, that will be waked with a MIG welder.

In welding the wire is the most essential part of the entire stick welding process. The wire known to be weld filler wire is metal given in the weld to create the weld joint. This weld filler wire which is given is what is melted to make the weld by melting to the base metal you’re welding on not like melting the wire type given but the weld is formed because the given melt it with the base metal to create the weld bond. The quality of wire you use to make the weld determines the overall quality of the weld you make.

The welding process being used will determine if you need a wire that is certifiably “suitable.”. A MIG / TIG wire would probably be best if you are using one of those processes. For flux cored arc welding (FCAW) or submerged arc welding (SAW) you must use a certain type of wire, generally you can use something like mild steel wire or even better a metal core wire. For most MIG welding you will want to use a mild steel wire. The only exception to this is if the project requires flux cored arc welding (FCAW) in which you will want a flux cored wire. Knowing what to evaluate in the welding process conditions can also really help in deciding the wire welding requirements required.

The main determinant in choosing the best welding wire for your application will be matching the needs of the application and what the weld is being used for the most with welding wire with matching mechanical properties. Certain applications will have different mechanical properties, just like certain welding wire will have different mechanical properties, such as heat distortion, corrosion, normal everyday wear and tear, etc. The only way that can help you decide how to select a particular welding wire for these welds, is to find a welding wire that is primarily used as a fail safe with these welds. Most of the time welds will be recommended as a particular welding wire because of how well certain metals are used for corrosion, or simply how well of a finish it will provide.


The diameter of the wire and the package of the wire you choose should be the application in which you are using the wire (subject to your needs) and the volume of wire you need to have stored (where the wire will be stored may be affected by the packages – spools, drums – and information on best storage should be attained of the wire you choose as long as it is stored in a dry area), whatever would be most convenient. The diameter of the wire being used depends on the cap of the welding equipment you are using and the capacity of your machines (which is also beneficial in determining the package size you should purchase and use).

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