Wire Feed Speed (WFS) Calculator
Calculate the required MIG welding wire speed based on amperage and wire diameter.
Understanding Wire Feed Speed (WFS)
In Gas Metal Arc Welding (GMAW/MIG), Wire Feed Speed (WFS) is the rate at which the filler metal is fed into the welding joint. It is measured in Inches Per Minute (IPM). WFS is the most critical setting because it directly controls the amperage of the weld. As you increase the WFS, you increase the current (amps), which leads to deeper penetration and a larger weld bead.
The Relationship Between Amps and WFS
Unlike Stick welding where you set the amperage on the machine, in MIG welding, you set the WFS and the machine provides the necessary amperage to melt the wire at that speed. The relationship is determined by the wire's diameter. Thinner wires require much higher speeds to achieve the same amperage as thicker wires.
How to Calculate WFS Manually
Professional welders often use "Multipliers" or "Constants" for carbon steel to estimate WFS. The basic formula is:
WFS = Amperage × Multiplier
| Wire Diameter | Multiplier (Steel) | Example (100 Amps) |
|---|---|---|
| 0.023″ | 3.5 | 350 IPM |
| 0.030″ | 2.0 | 200 IPM |
| 0.035″ | 1.6 | 160 IPM |
| 0.045″ | 1.0 | 100 IPM |
Optimizing Your Weld
While this WFS calculator provides a theoretical starting point, you must also adjust your Voltage. If the wire is stubbing into the metal, your voltage is too low or WFS is too high. If the wire is melting back into the contact tip, your voltage is too high or WFS is too low. Aim for the "bacon frying" sound for a stable short-circuit transfer.