Welding Reference Card
One page. MIG, TIG, stick and flux core settings by thickness.
$3.99
BuyWelding Amperage Calculator
MIG, TIG, Stick & flux-core starting amps by material thickness
Look up recommended amperage ranges using the same published data as our Welding Amperage Chart — interactive instead of scrolling tables. Amperage is a starting point; fine-tune from joint design, position, and bead inspection.
Welding
Complete Welding Settings Guide
19 pages. Four processes, stainless and aluminum, symbols and inspection.
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Welding Job Estimator
Price the job, then hand over a quote with no internal numbers.
Excel or Google Sheets. Best on a computer.
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Welding Complete Bundle
Card, 19-page guide and the estimator workbook. All six files.
Excel or Google Sheets. Best on a computer.
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Welders & amp verification
Machines with clear output ratings plus a clamp meter to verify actual arc current.
Lincoln Electric Power MIG 211i
- 210A class output on 120/230V
- Match chart amps to nameplate rating
- Auto-Set for wire speed (MIG)
- Dual voltage shop flexibility
Everlast Cyclone 200ES MIG
- 180A output at 110/220V
- Covers mid-chart thickness range
- Verify amps with a clamp meter
- Dual voltage for field work
YESWELDER MIG-205DS PRO 5-in-1
- 200A multi-process output
- MIG, TIG, Stick in one box
- Compare processes on same thickness
- 110/220V flexibility
Klein Tools CL800 Digital Clamp Meter
- Clamp-on AC/DC welding current
- Verify machine dial vs actual amps
- True-RMS for inverter welders
- Fine-tune from chart starting point
Weldpro 200A AC/DC TIG Welder
- Direct amperage control on TIG
- AC mode for aluminum chart range
- Foot pedal heat modulation
- Lower amps than MIG on same thickness
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Same data as the amperage chart guide
This calculator uses the identical reference ranges published in our Welding Amperage Chart — mild steel table plus stainless and aluminum adjustments scaled from that guide's published 1/8" examples (10–15% less for stainless, 25–35% more for aluminum). Flux-core uses the MIG column because the chart groups FCAW with MIG heat input. Numbers are starting points only; fine-tune from joint type, position, and bead appearance.
MIG vs TIG vs Stick vs flux-core
MIG draws higher amps than TIG on the same thickness because wire feed adds cold filler to melt. TIG is more efficient — direct amperage control with a non-consumable tungsten. Stick amperage follows rod diameter; material thinner than 11 gauge is below practical stick range on the chart. Flux-core mirrors MIG amps on the chart — use the dedicated Flux Core Welding Calculator for wire speed and voltage.
Material type adjustments
Stainless steel needs about 10–15% less amperage than mild steel because it conducts heat poorly and heat builds in the weld zone. Aluminum needs about 25–35% more because it pulls heat away from the arc — TIG aluminum requires AC. These multipliers match the examples in the chart guide (e.g. 1/8" mild MIG 130–150 A → stainless 115–135 A, aluminum 165–190 A).
Process-specific calculators
After you have a starting amperage range, dial in wire speed, voltage, tungsten, rod size, and gas with the process tools: