Miller Electric XLT 165, XLT 135 Typical MIG Process Control Settings, Wire Size Amperage Range

7-2. Typical MIG Process Control Settings

NOTE

These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications.

Material thickness determines weld
parameters.	1/8 or	Convert Material
	.125 in
		Thickness to
		Amperage (A)
		(.001 in = 1 ampere)
		.125 in = 125 A

.035 in

Wire Size	Amperage Range
.023 in		30 − 90 A
.030 in		40 − 145 A
.035 in		50 − 180 A

Select Wire Size

Wire	Recommendation		Wire Speed
Size			(Approx.)
.023 in	3.5 in per ampere	3.5 x 125 A = 437 ipm
.030 in	2 in per ampere	2 x 125 A = 250 ipm
.035 in	1.6 in per ampere	1.6 x 125 A = 200 ipm

Select Wire Speed (Amperage)

125 A based on 1/8 in material thickness

ipm = inch per minute

Low voltage: wire stubs into work

High voltage: arc is unstable (spatter)

Set voltage midway between high/low voltage.

Select Voltage

Voltage controls height and width of weld bead.

Wire speed (amperage) controls weld pe- netration (wire speed = burn-off rate)

Ref. 802 439

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