In TIG welding mild steel, the autogenous weld—fusing the base metal without a filler rod—is often a test of skill, but for nearly all structural and cosmetic applications, the right filler metal is essential for achieving strength, ductility, and a clean finish. The choice of filler rod is not merely a technicality; it directly influences the weld’s integrity, appearance, and resistance to cracking.
Navigating the world of TIG filler rods can be confusing, with classifications like ER70S-2, ER70S-6, and ER70S-3. Understanding the differences between the best 5 filler rods for TIG welding mild steel is the key to selecting the perfect one for your specific project, whether it’s a critical structural joint or a visible piece of custom fabrication.
The “ER” in these classifications stands for Electrode or Rod, the “70” indicates a tensile strength of 70,000 psi, and the “S” designates it as a solid wire. The number that follows (e.g., -2, -3, -6, -7) refers to the specific chemical composition of the rod, particularly the deoxidizing agents added to the wire.
These deoxidizers, such as silicon, manganese, aluminum, and zirconium, are crucial for scavenging oxygen and other impurities from the weld pool, which prevents porosity and ensures a solid, strong weld. For instance, ER70S-2 is a triple-deoxidized rod excellent for dirty, rusty, or oxidized steel, while ER70S-6, with higher manganese and silicon, provides a smooth arc and is the general-purpose champion for clean steel.
Choosing incorrectly can lead to a weak, porous weld, even with perfect technique. This guide will break down the best 5 filler rods for TIG welding mild steel, comparing their unique chemical properties, ideal applications, and the scenarios where each one shines, empowering you to make an informed choice for stronger, cleaner, and more professional results.
Our Top 5 Filler Rod For Tig Welding Mild Steel Recommendations at a Glance
Top 5 Filler Rod For Tig Welding Mild Steel Detailed Reviews
1. YESWELDER Mild Steel TIG Welding Rod ER70S-6 1/16″x16″ 5LB
Rating: 9.0/10
Tired of messy welds and extra cleanup? The YESWELDER ER70S-6 welding rods are here to make your mild steel projects smoother. These copper-coated carbon steel rods are designed for TIG welding and work well with different shielding gases. They help you get a clean, good-looking weld without a lot of fuss.
What We Like:
- High levels of manganese and silicon help create a smoother weld bead.
- Works great with 100% CO2 shielding gas for excellent results.
- Less spatter means less post-weld cleanup, saving you time.
- Versatile for many jobs, from construction to general shop work.
- Handles rusty or oily plates well, making it forgiving for less-than-perfect surfaces.
- Available in multiple diameters (1/16″, 3/32″, 1/8″) to fit your needs.
What Could Be Improved:
- Packaging can vary, which might be a minor surprise for some buyers.
If you’re looking for reliable TIG welding rods for mild steel that offer a cleaner weld and reduce cleanup time, the YESWELDER ER70S-6 rods are a solid choice. They’ll help you achieve professional-looking results on a wide range of projects.
2. TOOLIOM Mild Steel TIG Welding Rod ER70S-6 TIG Filler Rod 3/32″ x 16″ 5LB Welding Wire
Rating: 9.4/10
Let’s talk about the TOOLIOM Mild Steel TIG Welding Rod ER70S-6. This is a 5-pound pack of welding wire that’s just right for fixing and building things with mild steel. It’s a copper-coated rod, which helps it weld smoothly. You can use it with different shielding gases, making it flexible for your welding setup. The rods are a common size, 3/32 inch thick and 16 inches long, which works well for many projects.
What We Like:
- It’s great for welding at higher currents, which means you can get your work done faster.
- The arc it creates is steady, and you won’t see much spatter, leading to cleaner welds.
- It’s perfect for working with mild steel and low alloy steel, which are used in lots of common things like cars and bridges.
- The rods come neatly packed in a plastic case, so they stay organized and protected.
What Could Be Improved:
- While it works well, more detailed instructions on specific gas mixtures for optimal results could be helpful for beginners.
This TOOLIOM welding rod is a reliable choice for many steel projects. It offers good performance and makes welding easier.
3. SONNLER Mild Steel TIG Welding Rod ER70S-6 Welding Filler Rod 1/16″ x 16″ 5LB
Rating: 8.9/10
Tired of welding rods getting ruined by moisture? The SONNLER Mild Steel TIG Welding Rod ER70S-6 is here to help. This 5LB pack of 1/16″ x 16″ welding rods comes in a special, tough plastic package. This packaging is totally waterproof, so your rods stay dry even if they get wet. You can even use the package again! This makes it a great choice for anyone who welds regularly and wants reliable materials.
What We Like:
- The upgraded packaging is super waterproof and reusable, keeping your welding rods safe and dry.
- These rods are designed for low splatter, making your welding projects cleaner and easier.
- They offer good corrosion resistance, so your welds will last longer.
- SONNLER provides a worry-free experience with 30-day returns and a 2-year warranty.
- The rods come in popular sizes like 1/16″, 3/32″, and 1/8″ to fit different jobs.
- They work well with common aluminum alloys like 3003, 5052, and 6061, plus casing alloys.
What Could Be Improved:
- You need to use a shield gas, like 100% Argon or Argon/Helium, for best results.
- The product description lists “Most Popular Aluminum Wire” but these are mild steel TIG rods, which might be confusing for some users.
If you need dependable TIG welding rods that stay protected and deliver clean welds, the SONNLER ER70S-6 is a solid option. Its smart packaging and reliable performance make it a valuable addition to your welding toolkit.
4. SONNLER Mild Steel TIG Welding Rod ER70S-6 Welding Filler Rod 3/32″ x 16″ 5LB
Rating: 9.5/10
The SONNLER Mild Steel TIG Welding Rod ER70S-6 is a great choice for your welding projects. This 5LB pack of 3/32″ x 16″ rods is designed for TIG welding mild and low alloy steel. It promises low splatter and good corrosion resistance, making your welding jobs easier and your finished products more durable.
What We Like:
- The packaging is super strong and waterproof. Your welding rods will stay dry, even if they get wet. You can even reuse the box!
- These rods are made with ER70S-6, which means they have special stuff in them to make welding smoother.
- You get very little splatter when you weld with these rods. This means less mess and less work cleaning up after you’re done.
- They work well with different shielding gases, and more argon gas makes the weld bead look even better.
- These rods are perfect for many projects like fixing cars, building ships, making bridges, and working on machines.
- SONNLER offers a 30-day return and exchange policy, plus a 2-year warranty. You can buy with confidence.
What Could Be Improved:
- The description mentions multiple sizes (1/8″, 3/32″, 1/16″) but the product title specifically lists 3/32″. It would be helpful to clarify if this 5LB pack contains only 3/32″ rods or a mix.
Overall, the SONNLER ER70S-6 welding rods offer excellent performance and a user-friendly experience, backed by great customer service.
5. WISUNO Mild Steel TIG Welding Rods
Looking for reliable TIG welding rods? The WISUNO Mild Steel TIG Welding Rods, ER70S-6 TIG Filler Rod, measuring 1/16″ x 17″ and weighing 1LB, is a solid choice for your welding needs. These rods are made from copper-plated carbon steel and are designed for welding low-alloy and carbon steel. They are essential for TIG welding and help create strong, lasting welds.
What We Like:
- Easy to start the arc and keeps it very steady.
- Makes welds look nice and clean with little mess.
- Slag is easy to remove after welding.
- Works well for welding in any position, even overhead.
- Good for various projects in industries like shipbuilding and construction.
- Copper plating helps the rod feed smoothly and prevents rust.
What Could Be Improved:
- More detailed instructions for beginners could be helpful.
- Packaging could be more robust for shipping.
These WISUNO ER70S-6 welding rods offer great performance for many welding jobs. They are a dependable option for both beginners and experienced welders.
Choosing the Right Filler Rod for TIG Welding Mild Steel
TIG welding mild steel is a common and versatile skill. Using the correct filler rod makes a big difference in the strength and appearance of your welds. This guide helps you pick the best filler rod for your TIG welding projects.
Key Features to Look For
When you shop for filler rods, keep these important features in mind:
- Diameter: Filler rods come in different thicknesses. Choose a diameter that matches the thickness of the metal you are welding. A common rule is to use a rod diameter about the same as your metal thickness. For thin metal, use a thin rod. For thick metal, use a thicker rod.
- Length: Most filler rods are about 3 feet long. This is a good length for most jobs. Some rods are shorter or longer. Pick a length that feels comfortable for you to handle.
- Surface Finish: A smooth, clean surface on the filler rod is important. This helps the rod melt evenly and creates a clean weld. Look for rods that are not rusty or dirty.
- Packaging: Filler rods should come in a protective package. This keeps them clean and prevents them from bending. Many rods come in plastic tubes or sturdy boxes.
Important Materials
Mild steel filler rods are usually made from steel that is very similar to the mild steel you are welding. The most common type is ER70S-2 or ER70S-6.
- ER70S-2: This is a popular choice. The “70” means it has a tensile strength of 70,000 pounds per square inch. The “S” means it is a solid wire. The “-2” means it has added deoxidizers. These help remove impurities from the weld pool. This makes the weld stronger and cleaner.
- ER70S-6: This is another common and good option. It also has a tensile strength of 70,000 psi. It has more deoxidizers than ER70S-2. This makes it very forgiving. It works well even if your base metal isn’t perfectly clean.
Both ER70S-2 and ER70S-6 are excellent for mild steel. They create strong, reliable welds.
Factors That Improve or Reduce Quality
Several things affect the quality of your welds.
Improving Weld Quality:
- Cleanliness: Always start with clean base metal and a clean filler rod. Remove any oil, grease, rust, or paint. A clean surface helps the weld fuse properly.
- Proper Gas Shielding: Argon is the common shielding gas for TIG welding mild steel. It protects the weld pool from air. Good gas flow prevents contamination.
- Correct Heat Input: Too much heat can burn through thin metal or cause excessive warping. Too little heat leads to poor fusion. Find the sweet spot for your metal thickness.
- Consistent Travel Speed: Moving the torch at a steady pace creates a uniform weld bead. Jerky movements can lead to an uneven and weak weld.
Reducing Weld Quality:
- Dirty Filler Rods: Contaminants on the rod get into the weld. This can cause porosity (small holes) and weak spots.
- Incorrect Gas Flow: Not enough gas leaves the weld exposed to the air. Too much gas can cause turbulence and pull in contaminants.
- Using the Wrong Filler Rod: While ER70S-2 and ER70S-6 are great for mild steel, using a rod meant for a different type of metal won’t give you the best results.
- Lack of Practice: TIG welding takes practice. Without it, your welds might not be as strong or look as good.
User Experience and Use Cases
Most DIYers and professional welders find ER70S-2 and ER70S-6 filler rods easy to use. They melt smoothly and create a nice, clean bead.
Common Uses:
- Fabrication: Building custom parts for cars, bikes, or furniture.
- Repair Work: Fixing broken metal items or patching holes.
- Art and Sculpture: Creating decorative metal pieces.
- General Projects: Welding brackets, frames, or any project using mild steel.
For beginners, ER70S-6 is often recommended because its extra deoxidizers make it more forgiving of less-than-perfect base metal cleanliness. Experienced welders can use either with great success.
Frequently Asked Questions (FAQ)
Q: What is the best filler rod for TIG welding thin mild steel?
A: For thin mild steel, use a thin diameter filler rod, like 0.030″ or 0.035″. ER70S-2 or ER70S-6 are still excellent choices.
Q: Can I use ER70S-2 on dirty mild steel?
A: ER70S-6 is generally better for slightly dirty mild steel because it has more deoxidizers. However, always clean your metal as much as possible for the best results.
Q: What does the “ER70” mean on filler rods?
A: “ER70” means the filler rod has a minimum tensile strength of 70,000 pounds per square inch. This is a measure of how strong the weld will be.
Q: Do I need a special filler rod for galvanized mild steel?
A: Galvanized steel has a zinc coating. It’s best to remove the galvanization before welding. If you must weld it, use a filler rod like ER70S-2 or ER70S-6, but be aware of zinc fumes, which are toxic.
Q: How do I store filler rods?
A: Store filler rods in a dry place. Keep them in their original packaging or a sealed container to prevent rust and contamination.
Q: What is the difference between ER70S-2 and ER70S-6?
A: The main difference is the amount of deoxidizers. ER70S-6 has more deoxidizers, making it more forgiving of impurities in the base metal.
Q: Can I TIG weld mild steel without filler rod?
A: Yes, for very thin mild steel, you can sometimes fuse the edges together without filler rod (called “keyholing” or “edge fusion”). However, for most projects, a filler rod is needed to add material and strength.
Q: Is the diameter of the filler rod important?
A: Yes, the diameter is very important. Match the filler rod diameter to the thickness of the metal you are welding for the best fusion and weld appearance.
Q: What shielding gas should I use with mild steel filler rods?
A: For TIG welding mild steel, pure Argon is the most common and recommended shielding gas.
Q: Are there other types of mild steel filler rods besides ER70S-2 and ER70S-6?
A: While ER70S-2 and ER70S-6 are the most common and widely used for mild steel, there are other specialized rods. However, for general mild steel TIG welding, these two are the go-to choices.
In conclusion, every product has unique features and benefits. We hope this review helps you decide if it meets your needs. An informed choice ensures the best experience.
If you have any questions or feedback, please share them in the comments. Your input helps everyone. Thank you for reading.
I’m Darrell Julian, the founder, lead writer, and hands-on welding enthusiast behind ArcWeldingPro.com. With more than 15 years of real-world welding experience, I created this platform to share what I’ve learned in the field, in the shop, and in the heat of the arc.
