The right starting settings save hours of trial and error. Here's how to find them — and how to verify your weld actually came out right.
Every welder has been there: staring at a new joint, a new material thickness, and a blank settings dial. Welding calculator apps exist to solve this problem. They give you a starting point so you're not burning test coupons to dial in basic parameters.
But there's a catch. Calculators give you starting points. They can't tell you if your weld actually came out right.
A quality welding calculator app will handle most or all of the following:
Calculator outputs are starting points, not final settings. Material condition, fit-up, machine calibration, and your technique all affect the optimal settings. Always run a test bead and adjust.
The most comprehensive free welding calculator available. Covers GMAW, GTAW, SMAW, and FCAW with material-specific charts. Pulls directly from Lincoln's procedure database.
Miller's web-based calculator is the fastest way to get MIG and TIG settings. Enter your material type, thickness, and process, and it returns voltage, wire speed, and gas flow in seconds. Available at millerwelds.com and as a mobile-optimized page.
Free iOS/Android app with an intuitive interface. Covers stick, MIG, TIG, and flux-core. Includes a heat input calculator for compliance with welding procedure specifications (WPS).
Ed Craig's welding resource includes online calculators for MIG parameters, wire burn rates, and deposition efficiency. More technical than app-based tools but invaluable for process engineers.
| Material Thickness | Wire Size | Voltage | Wire Speed (IPM) | Gas (C25) |
|---|---|---|---|---|
| 1/16" (18 ga) | .023" | 14–16V | 150–200 | 20–25 CFH |
| 1/8" | .030" | 17–19V | 200–250 | 25–30 CFH |
| 3/16" | .035" | 18–21V | 250–320 | 25–35 CFH |
| 1/4" | .035" | 20–23V | 300–380 | 30–40 CFH |
| 3/8" | .045" | 23–27V | 280–360 | 35–45 CFH |
Note: These are flat position starting points for mild steel. Adjust +10–15% for overhead, -10% for vertical.
| Material / Thickness | Amperage | Tungsten | Filler Rod | Gas (100% Ar) |
|---|---|---|---|---|
| Mild steel 1/16" | 60–80A | 3/32" 2% thoriated | ER70S-2 1/16" | 15–20 CFH |
| Mild steel 1/8" | 100–130A | 3/32" 2% thoriated | ER70S-2 3/32" | 15–20 CFH |
| Stainless 1/16" | 55–75A | 3/32" ceriated | ER308L 1/16" | 15–20 CFH |
| Aluminum 1/8" | 110–140A AC | 3/32" pure/zirconiated | ER4043 3/32" | 20–25 CFH |
| Aluminum 1/4" | 200–250A AC | 1/8" pure/zirconiated | ER4043 1/8" | 25–30 CFH |
TIG settings are highly machine-dependent. Always verify with a test coupon.
| Electrode | Diameter | Amperage Range | Polarity | Best For |
|---|---|---|---|---|
| E6010 | 1/8" | 75–125A | DCEP | Root passes, pipe |
| E6013 | 1/8" | 80–130A | AC or DCEP/DCEN | Sheet metal, beginners |
| E7018 | 1/8" | 110–165A | DCEP | Structural, fill/cap passes |
| E7018 | 5/32" | 150–200A | DCEP | Heavy structural |
| E309L | 1/8" | 90–140A | DCEP | Stainless / dissimilar metals |
Here's what welding calculators are honest about if you read their fine print: they give you starting point parameters based on average conditions. They cannot account for:
This is where AI weld analysis closes the loop. After you dial in your settings using a calculator and make your first bead, DimeVision can analyze the bead photo and tell you if the settings are actually producing good fusion, whether there's porosity, undercut, or spatter that indicates a settings problem.
It's the difference between guessing your settings are right and knowing they are.
Use a calculator to find your starting point. Then upload a weld photo to DimeVision for instant AI analysis — find out if your settings are producing good welds or hiding defects.
Analyze My Weld Free →Last updated: March 24, 2026 | DimeVision Editorial Team