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Differences Between Carbon Steel and Mild Steel Welding Wire

Carbon Steel and Mild Steel Welding Wire

For welding professionals, having a good grasp of the differences between carbon steel and mild steel welding wires is essential. Not only can it affect the quality of your welds, but it can also influence the type of protective coatings you should use for your projects. In this blog post, we will explore the key differences between carbon steel and mild steel welding wire so that you can make informed decisions when selecting the best option for your job.

Carbon Steel vs. Mild Steel Welding Wire – Material Properties

The primary difference between carbon steel and mild steel is in their chemical composition. Carbon steel has higher levels of carbon, which makes it harder than mild steel but also more brittle. This means that carbon steel welds are ideal for projects that require superior strength and durability, while mild steel welds are better suited to applications where flexibility or malleability is needed.

Another key distinction between these two types of welding wire is their melting points. Carbon steel has a much higher melting point than mild steel; for example, an E6013 electrode (a type of carbon-steel electrode) requires an input voltage of around 70 Volts to reach its melting point, whereas an ER70S-6 (a type of mild-steel electrode) requires only about 50 Volts. This means that if you need to weld at higher temperatures, then using a carbon-steel rod would be more suitable than using a mild-steel rod.

Protective Coatings – Another Factor to Consider

It’s important to note that when selecting either carbon or mild-steel welding wire, one should also consider the type of protective coating required by the project at hand. Generally speaking, carbon-steel rods require heavier protective coatings due to their greater hardness and brittleness compared to those used with mild-steel rods. It’s important to select the right type of coating based on the application—for instance, stainless steels may require different coatings than aluminum alloys or cast iron—in order to ensure optimal performance in any given situation.


In summary, there are several key distinctions between carbon and mild steel welding wires that should be taken into consideration when selecting the best option for your project needs. The material properties associated with each type will determine whether you need greater strength or flexibility from your welds; likewise, the correct protective coating must be selected based on the application at hand in order to maximize performance and ensure optimal results from your welds every time! With this knowledge in mind, you’ll be able to make informed decisions about choosing the best wire for any given job requirement.

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