MIG Welding Estimator
Estimate the resulting Amperage from a given Wire Feed Speed (WFS), or calculate the required WFS to hit a target Amperage on your WPS.
Welding Parameters Estimate
Estimated Amperage
--
Amps
Recommended Voltage
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Volts (Approx)
Deposition Rate
0.0
lbs/hrCalculated volume times density minus typical spatter loss.
The Synergic Relationship
In MIG (GMAW) welding, the power source provides Constant Voltage (CV). The Amperage is directly controlled by the Wire Feed Speed. Pushing more wire into the joint requires more current to melt it.
Solid Steel Rule of Thumb
| Wire Size | Multiplier (IPM per Amp) |
|---|---|
| 0.023" (0.6mm) | 3.5 IPM |
| 0.030" (0.8mm) | 2.0 IPM |
| 0.035" (0.9mm) | 1.6 IPM |
| 0.045" (1.2mm) | 1.0 IPM |
| 1/16" (1.6mm) | 0.5 IPM |
Example: To run 200 Amps with 0.035" wire, you need roughly 320 IPM (200 × 1.6).
Material Differences
- Aluminum: Melts much faster and has lower resistance. You must feed Aluminum about 1.5x to 1.6x faster than steel to achieve the same amperage.
- Flux-Core (FCAW): Because the wire is hollow, it has less mass. You must feed it roughly 1.25x faster than solid wire of the same diameter to pull the same current.