2 Different Proper Gas Mixes

[JT Metalworks]

My 44# spool was only $55. So when you factor into things like bigger capacity, and better pricing, it makes the scales tilt even more in favor of MIG.

Using straight CO2 would cut gas cost in half as well, but that might be a bit harsh for doing sheet metal with.

[Shade Tree Welder]

Originally Posted by JT Metalworks

Someone else said something that I think makes a lot of sense about machine size: "If you can't burn through your work, your machine isn't big enough."

My 44# spool was only $55. So when you factor into things like bigger capacity, and better pricing, it makes the scales tilt even more in favor of MIG.

Using straight CO2 would cut gas cost in half as well, but that might be a bit harsh for doing sheet metal with.

I agree, but will add.

The Thermal arc wire (0.045) I have used is ~$1.00/pound and a 330 CF bottle refill is ~$40. I can go through ~135 pounds of wire per 330 CF of gas.

So my cost is $135+$40=$175 now figure in effeciency of 90% on Solid wire mig (135*.90=121.5) and my cost per pound of mig is $1.44.

Flux core runs 60% effiecent, and is ~$4/pound for FC wire so with 25# of wire you cost is $100 and your deposition is 25 * 60% or 15# so you cost per pound of deposition is $6.67.

Now with solid wire you job is fairly complete, with fluxcore you have to add you labor to clean up your weld.

I do not include the cost of the bottle here, because I consider that part of my equipment cost.

And if you have to worry about wire rusting then none of the above matters....

[JT Metalworks]

I was only including the bottle in the cost analysis because it is an expense in converting from flux core - the one salesmen use to keep people hooked on flux core.