Welding Filler Metals and Consumables by Process, Base Metal, and Diameter

E6011 and E6013 stick electrodes  · 

Start with the machine’s process and polarity, not the metal

A consumable only works if your welder can run it. Gas-shielded MIG wire runs electrode positive (DCEP) with a bottle of shielding gas and a solenoid. Self-shielded flux-core wire such as E71T-11 normally runs electrode negative (DCEN), so the machine needs a polarity lead you can swap at the terminals. Many entry-level 110V units do, but some have fixed wiring. Stick electrodes depend on the power source: E6010 needs DC electrode positive, while E6011, E6013 and E7018 run on DC and on most AC transformer machines. TIG on a DC-only machine can weld steel and stainless but not aluminum, which needs AC for oxide cleaning.

Check the spec plate for duty cycle and maximum amperage before choosing diameter. A small machine can feed a thick wire or hold a large rod, but it may not have the output to melt it properly. The usual result is cold lap, a ropey bead that sits on the surface, and an arc that stutters. Confirm the process, polarity and amperage range first. Then narrow by base metal and thickness.

MIG wire: ER70S-6 versus ER70S-3, and .023 versus .030 versus .035

For mild steel with shielding gas, ER70S-6 is the common default. Its higher manganese and silicon deoxidizers let it wet out over light mill scale and surface contamination. That makes it forgiving on typical shop steel. ER70S-3 is a cleaner-steel wire with a slightly different chemistry, and it suits well-prepped plate. Use either with 75/25 argon/CO2 for a smoother arc and less spatter, or 100% CO2 for deeper penetration and a harsher, spattery arc.

Diameter is set by thickness and by the power your machine can deliver. A .023 wire suits thin sheet and low-amp machines. A .030 wire covers a wide range from sheet to light structural work on small machines. A .035 wire carries more deposition and penetration for thicker sections, but it needs enough amperage. Then match the hardware: the contact tip bore must match the wire, and the drive roll groove must fit it. Solid wire uses a V-groove, knurled rolls are for flux-core, and aluminum wire needs a U-groove. Spool size matters too. A 2 lb spool, a 10 lb spool and a 33 lb spool use different hub diameters and spindle fits, so check what your feeder accepts before buying a larger spool.

Stainless MIG uses a different filler class such as ER308L or ER308LSi, with a stainless-rated gas. Aluminum MIG uses ER4043 or ER5356 with pure argon, plus a spool gun or push-pull feed to stop the soft wire birdnesting.

Flux-core wire: E71T-11, E71T-GS and gas-shielded E71T-1

The first question is whether your wire is self-shielded or dual-shield. E71T-11 and E71T-GS are self-shielded, so the flux core generates its own protective gas. That makes them practical outdoors or in wind, where a gas bottle would blow away. They run DCEN, throw more spatter than solid wire, leave a slag you chip off, and produce more smoke. E71T-GS is classified for single-pass work only, so it suits thinner material and light repair. Look at the manufacturer’s data sheet for E71T-11 thickness and multipass limits, because they vary by brand and diameter.

E71T-1 is a gas-shielded flux-core wire. It runs DCEP with CO2 or an argon/CO2 mix and gives a smoother arc and better bead appearance, with a slag that peels more easily. It needs a machine that handles gas and a feeder that grips the tubular wire without crushing it. Because the wire is hollow, over-tight drive roll tension flattens it and causes erratic feeding. Use knurled drive rolls and set tension just enough to feed. Flux also absorbs moisture, so an old, damp spool tends to produce porosity and a rough arc.

Stick electrodes: 6010, 6011, 6013 and 7018

The classification number tells you what you are buying. In E7018, the 70 means a minimum tensile strength of 70,000 psi, the third digit indicates the position the rod can be used in, and the last digits describe the flux coating and current type.

Diameter commonly runs 3/32, 1/8 and 5/32 inch. Thicker rods need more amperage, so match them to the output of your machine. The care requirement matters most with E7018. Its coating absorbs moisture from the air, and wet rods cause porosity and hydrogen-related cracking risk on thick or high-strength steel. Keep opened rods in a sealed canister or a heated rod holder, and follow the maker’s reconditioning instructions if they were left out.

TIG tungsten and filler rods: choosing by metal and current

Tungsten is a non-consumable electrode, but it is a purchase decision. Pure tungsten (green) was traditionally used for AC aluminum on transformer machines. Lanthanated tungsten (blue for 2%, gold for 1.5%) is a common all-rounder that works on both DC and AC. Ceriated tungsten (grey or orange) starts easily at low amperage on thin metal. Thoriated tungsten (red) is a low-level radioactive material, so grinding dust is a health concern. Many welders choose lanthanated or ceriated instead. Zirconiated (brown or white) is an AC option. Diameter commonly runs 1/16, 3/32 and 1/8 inch, and the collet, collet body and gas lens must match the diameter you pick. Grind a taper lengthwise for DC. On AC, an inverter machine can balance the arc with a slightly blunted tip.

For filler rod on mild steel, ER70S-2 contains additional deoxidizers (aluminum, titanium and zirconium) and tolerates less-than-perfect prep. ER70S-6 flows more fluidly thanks to manganese and silicon. For stainless, match ER308L to 304 and ER316L to 316, and use ER309L for dissimilar joints such as stainless to mild steel. On aluminum, ER4043 is silicon-bearing, flows and wets well, and resists cracking in many 6xxx alloys. ER5356 is a magnesium-bearing filler that is stronger and usually matches color better after anodizing. Avoid it for parts that see sustained elevated temperature. Rods are normally sold in 36 inch lengths, and a diameter close to the tungsten or thinner than the base metal works for most small jobs.

What more money buys, and how consumables fail

Higher-priced wire and rod generally buy tighter diameter tolerance, more consistent copper coating or flux fill, better cast and helix (how the wire leaves the spool), and cleaner packaging. Consistent wire feeds better and sticks less in the contact tip. Cheap or old spools can show uneven plating, flaking copper that clogs the liner, or rust bloom that causes burnbacks and porosity. With stick rods, the premium is more consistent coating concentricity and moisture-resistant packaging.

Plan for the failure modes. Porosity and wormholes usually trace to dirty metal, a damp consumable, a drafty site or inadequate gas coverage, not the wire class itself. Birdnesting at the drive rolls points to wrong groove type, excessive tension, a worn liner or a kinked cable. Burnback means the wire fused to the tip, often from a mismatched tip bore or low voltage. Store spools in a sealed bag with desiccant. Replace the liner when you change between steel and aluminum. Keep a small spare set of contact tips, nozzles and collets in your diameter so a single worn part does not stop a job.

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FAQ

Is ER70S-6 or ER70S-3 better for a home shop?

ER70S-6 is the more forgiving choice because its extra manganese and silicon help it tolerate light mill scale and surface contamination. ER70S-3 works well on clean, well-prepped steel. Most home shops that weld whatever material turns up pick ER70S-6.

Can I use E71T-11 flux-core wire on a MIG welder that has a gas hookup?

Yes, if the machine lets you reverse polarity to DCEN and has the right drive rolls. E71T-11 is self-shielded, so it does not need gas. Switch to knurled drive rolls for the tubular wire, and keep the V-groove rolls for solid MIG wire.

Should I use 4043 or 5356 aluminum filler?

Choose ER4043 for smoother flow, good wetting and lower crack sensitivity on many 6xxx base metals. Choose ER5356 when you need higher strength or a closer color match after anodizing, and avoid it for parts exposed to sustained high temperatures. For MIG, 5356 is also stiffer and feeds more reliably than the soft 4043 wire.