Welding Wire

For automotive and general garage tasks, common types are ER70S-6 mild steel MIG wire for sheet metal and chassis repair, flux-cored (FCAW) wire for out-of-position or outdoor welding, and stainless steel or aluminum wires for corrosion-prone parts and non-ferrous metals

Select wire diameter based on material thickness: thinner panels use 0.023–0.030 inch, general repairs 0.030–0.035 inch, and heavier sections 0.045 inch; use solid MIG wire with gas shielding (argon/CO2 mix) for clean joints and flux-cored wire when shielding gas is impractical or for thicker, dirty metal

Solid ER70S MIG wire is used with gas-shielded GMAW/MIG welding for clean, controlled welds; flux-cored wires are used with FCAW (self-shielded or gas-shielded) for faster deposition and outdoor work; aluminum wire requires a spool gun or push-pull feeder and argon shielding

Keep wire sealed and dry in its original spool or a sealed container, store in a low-humidity area, and for flux-cored or rutile wires consider using a desiccant or wire feeder with a sealed compartment to prevent rust and moisture absorption

Verify wire spool size and diameter match your welder/feeder capacity, ensure the drive rolls and liner are compatible with the wire type (soft, hard, or flux-cored), and confirm your machine supports the required shielding gas and current range for that wire

Use proper personal protective equipment (helmet, gloves, ventilation) to avoid fume inhalation and UV exposure, handle spool edges carefully to prevent cuts, and avoid using rusted or contaminated wire that can increase fume output and produce poor weld quality

Welding wire prices vary by type and spool size; budget options can be found under $50 for small spools, with a broad market range and average prices in the approximately $60–$100 area for common automotive-grade spools