MIG setup - "current-lead" method

By "current-lead" this means leading as in the first condition you focus on. That is, you work out the welding current you will need, then set up the MIG welding machine to get it. Here is advice as a was directed to it. Thanks to to Miller, makers of welding machines I can very much commend - based in Appleton, Wisconsin, USA.

In this method you use the "general rule", which applies not just to MIG but also to TIG and SMA welding, that you will be wanting about 1Amp of welding current per thousandth of an inch of material thickness. Or you can think of it as 40Amps per millimetre if you want to think in metric terms.

from
http://www.millerwelds.com/pdf/mig_handbook.pdf
- illustrated explanation on pg4

Setting up a MIG machine - current-lead method

(There is a voltage-lead method)

   Taking example of 1/8th-inch=0.125in (3mm) plate



Current<->thickness rule -- 1Amp per 0.001inch of thickness (40A per mm)

   So looking for 125A


Consider/survey/select wire size (diameter) options given their
current range.
Wire-size       |       Amp-range
0.8mm (0.030in) |       40-145A
0.9mm (0.035in) |       50-180A
1.2mm (0.045in) |       75-250A

   Each of these three wires accommodates the 125A needed


Deduce from known wire feed speed <-> current relationship the wire
feed speed needed, then set it with MIG machine's wire feed speed
adjuster

The w.f.s. <-> current relationships

Wire-size       |       Recommendation
0.8mm (0.030in) |       2 inches-per-minute per Amp
0.9mm (0.035in) |       1.6    -"-
1.2mm (0.045in) |       1      -"-

   So for our 3mm (1/8th-inch) weld, would be
   Wire-size            |   calculation   |   w.f.s.
   0.8mm (0.030in)      |   2 * 125       |   250ipm
   0.9mm (0.035in)      |   1.6 * 125     |   200ipm
   1.2mm (0.045in)      |   1 * 125       |   125ipm
   

Select voltage

Low voltage      ->   wire "stubbing"
Correct voltage  ->   smooth running (the "crackling" sound on dip-transfer)
High voltage     ->   arc unstable, spatter