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What Gas is Used for MIG Welding?

Date: 07-02-2025
MIG Welding Welding Gas

What Gas is Used for MIG Welding? Alphaweld Insights


The most common gases for MIG welding are pure argon for welding non-ferrous metals like aluminum, and argon/carbon dioxide (Ar/CO₂) mixes for general welding of steel. Pure argon creates a wider, shallow weld, while Ar/CO₂ mixes provide deeper penetration for steel.

Most beginners jump into MIG welding without thinking about the gas behind the process. But picking the wrong gas for MIG welding can wreck your welds and waste your time. Let's clear up which MIG welding gas suits your projects and why it matters for strong, clean results. If you're serious about getting proper results, check out this comprehensive guide on selecting gases for DIY applications.

Common Gases for MIG Welding

Pure Argon

Used for welding aluminum and other non-ferrous metals. Pure Argon creates a clean weld with little spatter, but with less penetration than CO₂.

Argon/Carbon Dioxide (Ar/CO₂) Mix

A blend, most commonly 75% argon and 25% CO₂, it's the go-to for most general welding on mild and stainless steel. The CO₂ increases penetration for steel, while the argon helps stabilise the arc and reduces spatter compared to using pure CO₂.

Argon/Oxygen

Used in small ratios to improve the weld pool and penetration on carbon and stainless steel.

Helium Mixes

Can be added to argon for thicker aluminium to increase heat input. Helium/Argon/CO₂ mixes can be used for stainless steel to minimise corrosion and improve weld quality.

Choosing Gas Based on Material

Mild Steel

For everyday mild steel welding, you have options:

  • 100% CO₂: Cheapest option, rougher welds

  • 75/25 Argon/CO₂: Best all-round choice for most projects

  • 90/10 Argon/CO₂: Premium choice for cleaner welds

Stainless Steel

Stainless steel requires different gas mixtures:

  • 90% Helium, 7.5% Argon, 2.5% CO₂: For thicker stainless

  • 98% Argon, 2% CO₂: For thin stainless steel

  • 90% Argon, 10% CO₂: Budget option that still works

Using standard mild steel mixes on stainless can lead to carbon contamination and reduced corrosion resistance.

Aluminium

Aluminium demands pure argon (100%). No CO₂ should be used as it will create brittle, porous welds. Pure argon provides the clean, oxide-free environment aluminium needs.

Practical Tips for MIG Welding Gas

Flow Rate Matters

Set your gas flow rate between 15-25 cubic feet per hour (CFH). Too little gas won't protect your weld; too much creates turbulence that pulls air into your weld pool.

Check for Leaks

Gas leaks cost you money and compromise weld quality. Check all connections with soapy water to spot bubbles that indicate leaks.

Gas Cylinder Storage

Store cylinders upright and secured to prevent falls. Keep them away from heat sources and electrical circuits.

Pre-Flow and Post-Flow

Use pre-flow to purge air from your lines before welding and post-flow to protect the cooling weld after you finish.

Final Thoughts

Choosing the right gas for MIG welding has a significant impact on the quality of your work. For most DIY welders, a 75/25 argon–CO₂ mix delivers the ideal balance of cost, control, and performance. If you’re welding aluminium, switching to 100% argon ensures cleaner, more consistent results.

Cutting corners on gas quality can lead to porosity, spatter, and weaker welds. The right MIG welding gas turns difficult jobs into strong, clean welds you can rely on.

For expert guidance, dependable support, and quality gear, trust the team at Alphaweld. Our specialists will help you choose the perfect setup for your application - no guesswork, no compromise.

Call us today on (08) 9456 8000 or email sales@alphaweld.com.au to speak with a welding expert.