Which Welding Rod for Thin Sheet Metal

Sheet metal welding is a heat management problem. The thinner the material, the faster it melts through. The right rod and technique keep the puddle controlled without blowing holes. MIG and TIG are generally better for sheet metal, but stick welding thin material is possible with the right electrode and settings.

Recommended Electrodes

ER70S-6

Best process for mild steel sheet metal. Use 0.023 or 0.030 inch wire with 75/25 Ar/CO2 at low voltage and wire speed. Pulse MIG if available. Short circuit transfer at low settings gives the most control.

Tensile: 70k psi Common Size: 0.023" Amps: 30-90A
Full amperage chart and specs

E6013

Best stick rod for sheet metal. The soft, low-penetration arc is forgiving on thin material. Use 3/32 or 1/16 inch diameter at the lowest amperage setting. Rutile coating bridges gaps without burning through.

Tensile: 60k psi Common Size: 3/32" Amps: 40-90A
Full amperage chart and specs

E6012

Excellent for sheet metal with poor fit-up. Heavy slag supports the puddle across gaps. Even gentler than E6013 on thin material. Use when gap-bridging is the primary challenge.

Tensile: 60k psi Common Size: 3/32" Amps: 40-90A
Full amperage chart and specs

ER4043

For aluminum sheet metal. Use 0.030 inch wire with 100% argon on MIG, or 1/16 inch rod on TIG with AC. Aluminum is even more prone to burn-through than steel due to its high thermal conductivity.

Tensile: 26k psi Common Size: .030" Amps: 50-130A
Full amperage chart and specs

Technique Tips

Use the smallest electrode diameter available. Move fast. Tack at close intervals before running continuous beads. Use skip welding or stitch welding to distribute heat and prevent warping. On sheet metal, appearance follows function: if you are not burning through, you are doing it right. For cosmetic work, TIG at low amperage with a small cup and gas lens gives the most control.

Common Mistakes to Avoid

Using E6010 or E6011 on sheet metal. Their deep-penetration arcs blow through thin material instantly. Using 0.035 MIG wire on sheet metal when 0.023 or 0.030 gives far more control at lower heat input. Running too slowly, which overheats the material. On thin metal, travel speed should be faster than you think.

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