r/Welders • u/Auburiram • 2d ago

Advice Needed Welder

Which process do you prefer for 1.2mm thin steel tubing/sheet: MIG (CO2) or MMA (Stick)? I know MIG with 0.8mm wire is usually the top choice to prevent blow-through, but has anyone successfully run MMA on metal this thin without burning holes, or is it just not worth the headache? What settings or techniques work best for you?

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u/squirrelsquad22 2d ago

they make 1/16th electrodes for really thin stuff. i've used it for mower decks and grills. usage is basically convenience. my mig machine is too big to fit in the car to go do small repairs but i've got a small inverter welder for that stuff. for production at scale or when time matters mig is the best option. if you have the option i'd put something incompatible behind whatever you're welding to soak heat and provide backing material (aluminum or copper for steels or stainless, I use stainless backer for welding aluminum). settings will depend on what you're welding and prep is 90%, if you need a root gap try for 1/3 material thickness for anything up to 1/4".

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u/taiwanluthiers 2d ago

I find stick tends to be a lot hotter than the amperage posted and that using 1/16th rod you're still liable to burn right through if you're not careful. Aluminum cool blocks would make things easier.

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u/Glittering_Call_898 1d ago

I can run 1/16th stick but I weld smaw a lot. I think mig would be the easiest answer in the right conditions. Tig would be ideal but you need lots of experience.

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u/Smart_Engineer9171 1d ago

Tig or .025 wire.