Welding Reference Card
One page. MIG, TIG, stick and flux core settings by thickness.
$3.99
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When the chart said the amps were right — but the puddle still lies
Use this when the Welding Amperage Calculator (and the master chart in the Amperage Chart Guide) pointed to a range, but beads burn through, lack fusion, or stick. Process-specific settings: MIG, TIG, Stick. MIG defect deep-dive: Common MIG Problems.
Amperage Failures Quick Answer
Most amp failures are wrong process chart, material mismatch (Al/SS vs mild), position not derated, machine maxed with no duty left, or travel/voltage fighting the amp setting.
| Symptom | Likely amp story | First fix | Next tool |
|---|---|---|---|
| Burn-through / hole | Too hot for thickness/process | Drop 10–20%; check process chart | Amperage Calculator |
| Cold lap / no fusion | Too cold or wrong process range | Raise amps; verify material type | Chart guide |
| Rod sticks / MIG stubbing | Low amps or wrong polarity/WFS pair | Match process calculator settings | Stick / MIG |
| OK flat, fails vertical | No position derate | Cut 10–20% for vertical | Chart guide position table |
| Good bead then thermal trip | Amps OK; duty cycle exceeded | Lower amps or cool-down plan | Duty Cycle Troubleshooting |
1. Using the Wrong Process Chart
What it looks like: Mild-steel MIG amps applied to Stick or TIG on the same thickness — burn-through or cold beads.
Fixes: Re-select process in the calculator. Never copy MIG numbers onto Stick rods.
2. Material Not Mild Steel
What it looks like: Chart “worked” on mild; stainless warps or aluminum melts through.
Fixes: Apply material adjustments from the chart guide; run a coupon before production.
3. Position Not Derated
What it looks like: Flat settings drip or undercut out of position.
Fixes: Use the position table in the chart guide; tighten travel technique.
4. Travel Speed / Voltage Fighting Amps
What it looks like: Amp set “by the book,” bead still ropey or burned — WFS/voltage or travel is the real variable.
Fixes: Hold travel steady; dial sister parameters on process calculators. MIG-specific defects: MIG problems guide.
5. Machine Ceiling and Duty Cycle
What it looks like: Chart wants 180A; 140A machine is pinned and trips.
Fixes: Size the machine to the chart’s thickness band, or change joint/process. Thermal trips: Duty Cycle Troubleshooting.
6. Fit-up and Joint Design Changing Heat Need
What it looks like: Open root or heavy fillet needs more heat than the butt-joint chart assumed.
Fixes: Adjust from coupons; see joint design guide for geometry context.
Article 3 & Chart — Already Covered
Article 3 SKIPPED: Machine sizing (120/240V bands), process differences, and position derates already live in the Amperage Chart Guide. Process technique stays on MIG/TIG/Stick calculators.
Chart SKIPPED: The guide slug contains “chart” and already functions as the Chart deliverable — master MIG/TIG/Stick amperage tables by thickness (same pattern as sheet-metal-gauge-chart / tap-drill-size-chart). No separate chart page.
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.
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Gear for Dialing Amperage Without Guesswork
Five CSV catalog picks with verified Product Image URLs.
Helmet
ARCCAPTAIN Auto-Darkening Welding Helmet
- See puddle clearly while tuning amps
- Shade range for MIG/TIG/Stick
- Wide view for position work
Gloves
Intra-FIT Cowhide MIG Welding Gloves
- Dexterity for travel speed changes
- Long cuff for heat at higher amps
- Shop staple
Rod
YESWELDER E7018 1/8in 10LB
- Stick amp windows by diameter
- Don’t copy MIG amp charts to stick
- Weigh stubs after amp trials
Wire
MIG Wire ER70S-6 .035in 10LB
- Match wire size to amp range
- Stable arc for test coupons
- Common fab diameter
TIG
WelderElite 123 Pcs TIG Torch Kit
- Consumables for amp/tungsten trials
- WP-17/18/26 common torches
- Keep cups/collets matched
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Frequently Asked Questions
Is the amperage chart guide already the Chart article?
Yes — it centers on master tables by thickness/process. This troubleshooting page diagnoses bead failures after you use those numbers.
Should I raise amps when the rod sticks?
Often yes for Stick — but confirm rod diameter, polarity, and arc length before jumping 40A.
Related Calculators & Guides
Convert Wire Feed Speed and Amperage
Convert measured IPM to estimated welding current—or amps back to starting IPM—with the Wire Feed Speed to Amps Calculator. Diameter-specific tables, burn-off factors, voltage pairing, and the six-second feed test are in the Wire Feed Speed Chart Guide.
Size the Welder Supply Circuit
For panel-to-receptacle building wire, use nameplate input current with the Wire Gauge Calculator for Welders. Then use the canonical Welding Wire Gauge Chart to keep branch wire, extension cords, welding leads, and MIG/TIG filler sizes separate.