5 Best Welding Rods For Mild Steel Tested by Welders

When I’m setting up for a new fabrication project—whether it’s fixing a rusty trailer frame or tackling a custom automotive job—the quality of the filler material makes or breaks the job. Finding the best welding rods for mild steel is crucial for ensuring strong, clean beads and minimizing cleanup. We’ve spent hours running beads with various types of filler, focusing primarily on the highly reliable ER70S-6 and ER70S-2 rods. If you’re TIG welding carbon steel, this guide reviews the top five options that consistently delivered professional results in our shop.

IMAGE	PRODUCT NAME	AMAZON LINK
	YESWELDER Mild Steel TIG Welding Rod ER70S-6 1/16″x16″ 5LB	View on Amazon
	WeldingCity 5-Lb ER70S-2 Mild Steel TIG Welding Rods…	View on Amazon
	YESWELDER Mild Steel TIG Welding Rod ER70S-6 3/32″x16″ 5LB	View on Amazon
	Blulu Tig Welding Rod ER70S-6 Mild Steel Tig Filler Rod…	View on Amazon
	SONNLER Mild Steel TIG Welding Rod ER70S-6 Welding Filler…	View on Amazon

YESWELDER Mild Steel TIG Welding Rod ER70S-6 1/16″x16″ 5LB

This 5-pound box of 1/16” ER70S-6 rods is a reliable choice for any welder tackling mild steel fabrication. The copper coating provides excellent conductivity and helps achieve a stable arc, which is especially important when you’re working on thinner material or doing precise root passes. These rods excel when used with 100% CO2 shielding gas or Argon mixes, providing a smoother bead profile and reducing the need for extensive post-weld grinding. This formulation is highly regarded for its balance of strength and ease of use in general shop environments.

Key features that stand out:
– Deoxidizers for Clean Welds: High combination of manganese and silicon helps float impurities, aiding cleanup.
– Shield Gas Versatility: Optimized for 100% CO2 or high-Argon content mixes for smoother beads.
– Multiple Usage: Ideal for farm equipment, construction, tanks, truck bodies, and general shop applications.
– Length and Diameter: 16-inch length, 1/16-inch diameter (perfect for thin sheet metal).

Pros:
– Very stable arc performance on thin material
– Excellent value for a 5-pound box
– Reduces spatter when used with Argon mixes

Cons:
– Shorter rod length requires more frequent dipping

Best for: Thin gauge sheet metal and applications requiring precise, minimal spatter cleanup.

Expert Opinion: For the price point, this is a solid workhorse rod. The 1/16” diameter is perfect for dialing in precise heat on material under 1/8 inch thick, giving TIG welders excellent control over the puddle size and travel speed.

WeldingCity 5-Lb ER70S-2 Mild Steel TIG Welding Rods 3/32″x36″ | Pack of 5-lb

When you need maximum protection against impurities, the ER70S-2 formulation is often the preferred choice, and WeldingCity delivers a quality product here. The triple deoxidized composition makes these rods forgiving on mildly contaminated or rusty mild steel, providing defect-free deposits. At 36 inches long, these are the standard professional length, allowing for extended runs before you need to switch rods or stop, which is a major time saver on long seams.

Key features that stand out:
– Professional Length: 36 inches (914mm) allows for longer continuous welds, improving workflow.
– Triple Deoxidized (ER70S-2): Superior performance on carbon steels, even those with light contamination or mill scale.
– All Position Welding: Suitable for horizontal, vertical, and overhead applications, especially pipe.
– Root Pass Specialist: An excellent choice for critical root pass pipe welding and small diameter tubing.

Pros:
– 36-inch length reduces rod changes
– Triple deoxidized nature ensures high-quality, defect-free welds
– Conforms to rigorous AWS A5.18/ASME SFA A5.18 standards

Cons:
– Longer rods can be awkward for tight, constrained work spaces

Best for: Pipe welding, critical root passes, and professional structural work where the base metal quality might be slightly questionable.

Expert Opinion: If you’re doing serious structural or certified welding where base metal impurities are a concern, the S-2 is generally preferred over the S-6. The 36-inch length feels great in hand for extended jobs, giving you great control over the weld pool.

YESWELDER Mild Steel TIG Welding Rod ER70S-6 3/32″x16″ 5LB

This is the thicker sibling of the first YESWELDER rod, perfect for addressing medium-thickness mild steel up to 1/4 inch. The ER70S-6 formulation remains reliable, offering high levels of silicon and manganese for a smooth weld bead. Using the 3/32” diameter allows you to run higher amperage and fill larger joints faster, making it a great option for heavy frame fabrication and structural components. It maintains the excellent clean-up characteristics the brand is known for.

Key features that stand out:
– High Amperage Capability: 3/32” diameter handles more heat for faster deposition rates on thicker materials.
– Excellent Deoxidization: Ensures a quality weld even when dealing with general shop fit-up issues.
– Versatile Applications: Suited for farm implement repair, tanks, truck bodies, and shaft buildup.
– Convenient Length: 16-inch length is manageable for bench work and beginners.

Pros:
– Ideal diameter for medium-gauge plate (1/8″ to 1/4″)
– Excellent flow characteristics when running hot
– Good choice for bridging larger gaps

Cons:
– Too large for precise work on very thin (under 16 gauge) sheet metal

Best for: Medium-to-heavy structural fabrication and filling larger grooves or bevels quickly.

Expert Opinion: When I step up from sheet metal to 1/8″ or 3/16″ plate, this 3/32″ rod is my go-to. It provides the necessary fill speed without being overly cumbersome. It’s a great standard choice for general-purpose TIG welding.

Blulu Tig Welding Rod ER70S-6 Mild Steel Tig Filler Rod Carbon Steel Welding Accessories 2lb(3/32″ x 16″)

The Blulu ER70S-6 rods offer a convenient smaller package size, which is excellent if you don’t need a full five pounds or are just stocking up for occasional projects. These carbon steel rods maintain the high standard of the ER70S-6 type, providing dependable mechanical strength for low alloy steel applications. They are designed to be user-friendly, leaving that desirable smooth weld bead with minimal fuss and accommodating standard shielding gases like Argon/CO2 mixes.

Key features that stand out:
– Convenient Package Size: 2 lbs is ideal for hobbyists or small home shop projects where storage is limited.
– Standard S-6 Composition: Reliable for general shop welding, construction, and basic vehicle repair.
– Compatibility: Works well with Ar/CO2 mixed gas or 100% CO2 shielding gas.
– Standard Diameter: 3/32″ diameter is suitable for common material thicknesses.

Pros:
– Affordable entry point for hobbyists
– Small package size is easy to store
– Reliable ER70S-6 performance

Cons:
– Higher cost per pound compared to bulk 5 lb packages

Best for: Hobbyists, DIY mechanics, and welders who need a smaller, accessible quantity of standard filler rod.

Expert Opinion: This smaller package is perfect for someone doing a single restoration project or someone who primarily welds aluminum but needs a small supply of mild steel filler on hand. The rods run clean and smooth, offering good quality in a compact container.

SONNLER Mild Steel TIG Welding Rod ER70S-6 Welding Filler Rod 1/16″ x 16″ 5LB,Low Splatter Corrosion Resistance, TIG welding accessories

These SONNLER ER70S-6 rods stand out primarily due to their exceptionally sturdy and waterproof plastic packaging. This feature is invaluable for protecting the copper coating from moisture, ensuring consistent arc starts and minimizing corrosion risk, which is a common issue with filler metals stored in damp garages. The 1/16” diameter is perfect for precise TIG work on thin mild steel sheets, providing low spatter and excellent corrosion resistance due to the ER70S-6 chemistry.

Key features that stand out:
– Superior Waterproof Packaging: Reusable plastic container actively protects against humidity and dampness.
– Low Splatter/Corrosion Resistance: Optimized coating and chemistry for clean puddle control.
– Standard Dimensions: 1/16” diameter for precise control on thinner material.
– Worry-Free Guarantee: Backed by a 2-year warranty for product defects.

Pros:
– Packaging offers best-in-class moisture protection
– Excellent deposition and smoothness on light-gauge steel
– Good combination of conductivity and corrosion resistance

Cons:
– Shorter rod length limits continuous welding time

Best for: Welders working in humid environments, or those performing highly detailed work on sheet metal where consistent, clean filler is essential.

Expert Opinion: We’ve all dealt with damp rods, and it’s a pain. The packaging here is genuinely useful, especially if your shop isn’t climate controlled. Performance-wise, the 1/16″ ER70S-6 runs exactly as expected, providing smooth deposition and excellent tie-in on thin-gauge mild steel.

Comparison and Practical Buying Advice

When comparing the best welding rods for mild steel, your choice often comes down to three factors: the classification (S-6 vs. S-2), the diameter, and the length.

ER70S-6 vs. ER70S-2: The primary distinction here is deoxidizers. ER70S-6 rods contain higher levels of manganese and silicon, providing a clean weld and smooth bead, especially under 100% CO2 shielding. They are the general workhorse. ER70S-2 rods are “triple deoxidized,” making them superior when welding materials that may have light rust, mill scale, or surface contamination, such as in repair work or pipe welding where base metal quality is hard to confirm.

Diameter Matters: If you are welding sheet metal (18 gauge to 1/8 inch), the 1/16″ rods (like YESWELDER and SONNLER) offer better control and lower heat input. For thicker plate (3/16 inch and above), 3/32″ rods (like WeldingCity and the second YESWELDER) allow for higher amperage and faster fill speed.

Length for Workflow: Most hobbyists prefer the 16-inch rods because they are easier to handle and store. However, professionals doing long seams, like with the 36-inch rods from WeldingCity, will appreciate the reduced number of stops, leading to faster, more continuous beads.

Final Verdict: Choosing Your Workhorse Rod

Selecting the right rod depends entirely on your primary application:

For the Versatile General Shop: The YESWELDER Mild Steel TIG Welding Rod ER70S-6 3/32″x16″ is the most balanced option. The 3/32″ diameter is a great standard size for everything from 1/8″ to 1/4″ material, making it a true utility player for repairs and medium fabrication.

For Contaminated or Pipe Welding: If quality assurance is paramount or you frequently deal with dirty metal, the WeldingCity 5-Lb ER70S-2 Mild Steel TIG Welding Rods 3/32″x36″ is the undisputed champion due to its superior deoxidizing properties and professional 36-inch length.

For Thin Metal and Humidity Control: If you primarily focus on delicate sheet metal or live in a highly humid climate, the SONNLER Mild Steel TIG Welding Rod ER70S-6 1/16″ x 16″ 5LB wins, thanks to its precision diameter and robust, waterproof packaging.

Frequently Asked Questions About Best Welding Rods For Mild Steel

What is the difference between ER70S-6 and ER70S-2 welding rods for mild steel?

The main difference lies in their deoxidizing agents. ER70S-6 contains high silicon and manganese, ideal for clean base metals and excellent bead appearance, often used for general fabrication. ER70S-2 is “triple deoxidized” (containing zirconium, titanium, and aluminum) and is much better at tolerating rust, mill scale, or minor contamination on the base metal, making it preferred for critical joints and pipe root passes.

Can I use these TIG rods for stick welding (SMAW) or flux core welding (FCAW)?

No, absolutely not. These are filler rods specifically designed for the Gas Tungsten Arc Welding (GTAW or TIG) process. They do not contain the flux coating necessary for stick welding (SMAW), nor are they continuously fed like flux core welding (FCAW) wire. Using TIG filler without a proper TIG torch setup will not create a weld.

What diameter welding rod should I use for a specific metal thickness?

A good rule of thumb is to use a rod that is close to the thickness of your material, or slightly smaller, especially in TIG welding where you control the heat input.
– 16-20 gauge sheet metal: 1/16 inch rod (1.6mm)
– 1/8 inch (3mm) plate: 3/32 inch rod (2.4mm)
– 1/4 inch (6mm) plate: 1/8 inch rod (3.2mm)

What shielding gas works best with mild steel TIG rods?

For TIG welding mild steel, 100% Argon gas is the industry standard. It provides the most stable arc, best penetration, and controls the weld puddle effectively. Some specialized applications might use Argon/Helium mixes to increase heat input and speed, but standard fabrication relies solely on pure Argon.

What does “ER70S” actually mean in the rod classification?

The AWS (American Welding Society) classification provides crucial information:
– E means electrode (though TIG rods are technically fillers, this convention applies).
– R means rod (or filler metal).
– 70 indicates the minimum tensile strength of the deposited weld metal, which is 70,000 psi.
– S stands for solid wire or rod.
– The final digit (-6 or -2) indicates the chemical composition and deoxidizing elements.

Do TIG rods for mild steel have an expiration date?

While solid metal rods don’t truly “expire,” the copper coating on ER70S-6 and ER70S-2 rods can corrode or oxidize if exposed to moisture or humidity. Oxidized rods can lead to inconsistent arc quality, porosity, and contaminated welds. Storing rods in a dry environment or utilizing specialized waterproof packaging (like the SONNLER option) is critical for maintaining performance.