.030 vs .035 Flux Core Wire: Which One Is Better!

Comparison between .030 vs .035 flux core wire is not easy until you’re an experienced welder. Being a novice welder, you may feel difficult to choose the right size for you. Sometimes, professionals even have to go through confusions while tend to choose the flux core wire.

Today, we will discuss the fundamentals of the flux core wire so that you can identify the right size for you.

Probably you know all of them or somethings unique is waiting for you in our next headings.


What Is Flux Core Wire?

Flux core is a special welding wire used for both 110V MIG and 220V MIG. It makes the welder weld without additional shielding gas. So, those who don’t want the extra hassle of shielding gas tank in the welding machine can only rely on the best alternative flux core wire.

The flux core is designed in such a way that it melts flux core wire to supply filler for the metal you’re going to weld.

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Why Flux Core Is Used?

Flux core is mostly used for the outside sphere where the weather can cause issues with MIG welding. Sometimes, the location’s weather causes much hassle to the welding. In those cases, you should get the flux core wire rather than using the shielding gas tank.

So, ultimately a flux core wire is an ideal choice to handle with tough weather.



There are multiple advantages that a flux-cored wire user will get only.

Let’s know them!

  • It reduces cost since it doesn’t need any gas tank to operate.
  • The deposition rates are higher than GMAW and SMAW.
  • Faster speeds to weld through materials.
  • Applicable for mild steel construction.
  • It consumes less time for changing electrodes.
  • Less spatter welding.


What Are The Benefits Of Welding With Flux Core Wire?

There are some highlighted advantages of flux-cored wire in our shortlist that we may want to share with all the desperate welders out there.

  • It’s not always welders get clean and even materials to weld. Most of the professionals tend to work with old and rusty materials often. So, they need flux-cored welding wire for their MIG welding tasks. Since there are welders who only work with clean metals, they are quite comfortable with only solid welding wire.
  • The high deposition rate is something every welder wishes for but hardly get the satisfying experience. You can easily produce a high deposition rate through flux wire.
  • FCAW produces the right amount of filler materials and makes an all-position welding process.
  • Welders who have to work in extreme stormy weather, they can gladly work with this without any inconvenience.


Disadvantages Of Flux Cored Wire:

There is some malfunctioning activity you may also face with it. Let’s know them. 

  • If the electrode isn’t well balanced then it would not able to occupy a complete fusion among the base and materials.
  • Sometimes, FCAW can cause cracks in the materials. Sometimes the slag inclusion mostly occurs while semi-automatic or automatic arc welding process is applied.
  • If the gas is jammed in the metal before getting the solid form, the weld may create holes in it.


Which Wire Should You Choose?

Which wire is better for the welding? If we dig into the real scenario of 030 vs 035 flux core wire, then we may determine the real stage.

What do those two size numbers (.35 and .30) mean? These are the different diameter sizes mostly used for the welding purpose.

As far as the term of the number, you already know the .35 wire is .5 thicker than the .30 inch wire. The rod’s dimension reflects on the thickness and capability of the road.

So, how to choose among them? If you go for the thicker .35-inch option then you must have to work with high amperage. While the thinner .30-inch is eligible with less amperage.

On the other hand, being a welder, you don’t only work with only thin or thick metal all the time. Well, .30 is fine on the thin metal sheet but won’t be ideal for welding thick metals.

And having high amperage durability, .35 works greatly on thick metal sheets but can crack or break the thin sheet. The thick metal should be around or more than 16 gauge to weld with .35 wire.

Since thicker metal sheets require extreme hot pressure, you will need to work more than .35 while the metal is all way too thick. If you tend to work with ½ inch thick metal sheet, then you must have a .45-inch core wire for welding.


Final Words:

From MIG welding to CNC cutter machine, flux cored wire is usually used welding, cutting, and shaping the tools. Most of the mini or giant welding machines come with a flux core wire. If you don’t have the right size yet, you can get one ordered online. They are cheap, easy to use, and hardly get damage after many usages.

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So, are you still stuck between the .030 vs .035 flux core wire? If you still have a query, comment us or email us directly. We’ll response in a short time and till then enjoy welding and keep making metal pieces.