035 Welding Wire

Achieve the perfect balance of penetration and control with the 035 welding wire collection from ArcCaptain. Whether you are fusing thick structural steel or detailing stainless parts, this wire diameter offers the versatility needed for high-quality beads and deep fusion. 

You get a consumable that feeds smoothly and burns consistently, ensuring your welds hold strong against the toughest stress tests.

Master Medium to Heavy Projects with 035 Welding Wire

Don't limit your potential with wire that is too thin for the job. Our 035 welding wire provides the higher deposition rates required to fill joints efficiently on material up to 1/2 inch thick. You gain the ability to run hotter and faster, laying down professional-grade welds in a single pass without sacrificing control.

• Excellent Deposition: Fills gaps quickly and ensures solid root penetration on thicker metal plates.
• Versatile Application: Ideal for automotive frames, farm repairs, and heavy fabrication work where strength is non-negotiable.
• Smooth Feeding: Precision winding prevents tangles and ensures a steady arc throughout the entire spool.

Choose the Right 035 Welding Wire for Any Environment

Your environment dictates your tools, and we offer the specific wire chemistry to match. Select our ER70S-6 solid wire for clean, gas-shielded shop work, or grab the E308LFC-O flux-cored option for wind-resistant stainless welding outdoors. We provide the exact 035 welding wire needed to adapt to your workspace conditions without compromising quality.

• Gas-Shielded Precision: Use solid wire with mixed gas for spatter-free, aesthetic welds on clean steel.
• Outdoor Durability: Flux-cored options protect the weld pool in windy conditions without the need for external gas tanks.
• Stainless Capabilities: Specialized stainless wires resist corrosion and maintain structural integrity in harsh elements.

Experience Clean Arcs and Minimal Spatter

Poor quality wire leads to erratic arcs and hours of post-weld grinding. Our wires are manufactured with strict chemical consistency to ensure a stable arc and minimal spatter accumulation on your nozzle. You spend less time chipping away slag and more time laying down stack-of-dimes beads that you can be proud of.

• Consistent Chemistry: Uniform copper coating on mild steel wires improves conductivity and arc stability.
• Reduced Cleanup: Lower spatter levels mean less grinding and a cleaner final appearance for your project.
• Stronger Bonds: High silicon and manganese content helps deoxidize the puddle, preventing porosity and defects.

Explore Related Collections

Stock up on the essential consumables that keep your shop running smoothly.

• Flux Core Welding Wire - Shop our self-shielded wires designed for outdoor use and welding on dirty or rusty metal.
• Gasless MIG Wire - Find the perfect solution for portable welding setups that don't require heavy gas cylinders.
• Mild Steel MIG Wire - Browse our premium solid wires optimized for general fabrication and automotive bodywork.

FAQs About 035 Welding Wire

How thick of metal can I weld with .035 wire? 

The .035 wire is a versatile "middle ground" size. It is typically best suited for metals ranging from 1/8 inch up to 1/2 inch thick. For thinner sheet metal (like auto body panels), .030 or .023 is usually better to prevent burn-through. For extremely thick plate (over 1/2 inch), you might need multiple passes.

Do I need gas for .035 welding wire?

It depends on the type of wire. If you are using solid wire (like ER70S-6), yes, you need a shielding gas (usually a mix of Argon and CO2). If you are using flux-cored wire (like E71T-GS), you do not need external gas because the flux inside the wire creates its own shield as it burns.

Is .035 wire better than .030?

"Better" depends on the application. The .035 wire carries more current and deposits metal faster, making it better for thicker materials and structural work. The .030 wire is better for thinner metals where you need more control to avoid burning a hole through the workpiece.

What polarity should I use?

For solid .035 wire with gas, use DCEP (Direct Current Electrode Positive). This puts the heat into the wire for smooth melting. For gasless flux-cored .035 wire, use DCEN (Direct Current Electrode Negative). This puts the heat into the workpiece to ensure good penetration.

Can I use stainless steel wire in my regular MIG welder?

Yes, as long as your welder can handle the wire diameter. However, you must use the correct gas (Tri-mix or 98% Argon) for solid stainless wire. ArcCaptain also offers gasless flux-cored stainless wire which allows you to weld stainless steel without a gas tank.