030 vs 035 Flux Core Wire: Detailed Comparison 2022

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It’s never easy. 

Judging differences between two similar flux core wires will never be easy. However, they arrive with quite some differences. Here, the main difference between them is the diameter. 

Due to the difference in diameter, both work differently on thinner and thicker metals. Hence, if you’re trying to choose one, things might get dicey. 

No need to worry, we have it under control. We’ve researched for a bit and have brought out this 030 vs 035 flux core wire comparison article. 

And, we haven’t stopped there. We’ve even taken a leap forward and highlighted the pros/cons of each wire in detail. 

Sounds interesting? We’ve got a lot in store for you. So, let’s begin-

Comparison Table

Common Grounds030 Flux Core Wire035 Flux Core Wire
Used onThin MetalsThick Metals

Similarity-Based on Different Factors

First things first, you’ll need to know that these two wires are pretty much the same. As they’re both flux core wires, you won’t face many differences in the purpose.

Plus, these wires function the same as well. So, you can use them in facilitating higher deposition rates. This makes them perfect at working in windy conditions.

So, when it comes to similarities, there’s quite a lot to focus on. 

Comparison Based on Different Factors

The Diameter

Starting with the obvious difference between the two core wires- the diameter. Here, the numbers that you observe at the beginning of these wires- 030 and 035 are the diameters of the rods.

So, the obvious difference between the two models is the change in diameters between them. And, the numbers in front of the rods indicate how much thickness the welding rod has.

The Thickness

035 core wire denotes that the electrodes are thicker and are measured “035 by 0.005 inches”. Even though you won’t find many differences here, the slight change can still affect the welding quality.

On the other hand, thick rods require high amperage when compared with thinner rods. So, a 035 flux wire will require higher amperage all the time. When compared between the thin 030 core wire, the thicker 035 core wire will need more.

In short, when it comes to welding thicker sheets of metal, it’s better to stick to a 035 welding wire. As the wires have higher amperage, you can easily work on thicker metals with this one. However, they’ll struggle a bit with thinner metals.

But, when it comes to thinner metals, the 030 core wires take the upper hand. They’re excellent when working with thinner metals.

Penetration Ability

Other than that, if you focus on the penetration ability of these wires then there’s a different story. Normally, the thicker the wire’s diameter, the penetration will be deeper in it. So, you’ll need to choose subjectively.

Now, coming to machine compatibility, the 035 core wires work great with all kinds of 250V machines. Whereas, the 030 core wires provide maximum performance with the 210V machines.

As we’re done breaking the comparison based on the different factors, let’s provide an overview of these two wires.

030 Flux Core Wire: Overview

51PECKbcoqL. SL500

Starting off with the 030 core wires, you’ll have a lot to admire. Firstly, the wires have the amazing capability of welding galvanized metals and body parts. It can even work at different materials and weld them effectively.

And, when this welding wire is showing its magic, people admire it for its smoothness and greater beads. In fact, it runs quite smoothly and can lay down a greater bead.

On the other hand, this wire works better with all kinds of thinner metals. And, the cleaning process is even simple and easy. So, you won’t have to put in extra effort and even your time will be saved.

Another great feature about this wire is that it won’t produce additional fumes and spatter. So, you can use them on indoor applications too with precautions.

Besides, you won’t require any outer gas containers when working with this welding wire. Now, coming to the wire diameter, you won’t have to worry. This is because the diameter remains consistent all the time.

Lastly, if the welder has around 190 AMP, go ahead and use this welding wire for yourself.


  • Provides a smooth run all the time.
  • Doesn’t cause much smoke and spatter.
  • Has a higher deposition rate.
  • Comes at an affordable price.
  • Works well with thinner metals.


  • Struggles with thicker metals.

035 Flux Core Wire: Overview

41zRNvN96PL. SL500

We’ve seen that the previous wire works great with thinner metals. However, if you’re looking for a welding wire on a thick metal then this is the choice. The 035 core wires work the best on thicker metals.

So, it doesn’t matter whether you’re working on carbon steel or galvanized steel-  the core wire will be able to perform the works easily.

Now, let’s focus on the freezing characteristics of the wire. With a freezing characteristic, the wire becomes easy to be used on multiple applications.

Besides, the wires can be used in windy conditions and have an impressive bead appearance.

However, the only caveat with this welding wire is that it’ll need huge power before operating. In fact, some welding machines can’t even produce the amount of power needed for this welding wire.

Hence, you’ll need to consider the welder before you even choose this wire and its functionality. Other than that, using this with the right welder will make things run smoothly and easily.

Apart from that, these wires have a bad reputation for giving off huge chunks of spatter. But, all of the models don’t actually produce this much spatter in the first place.

So, you’ll need to choose the models carefully. This will save up a lot of time in the clean up as well. And, you can even invest in an anti-spatter spray in order to make things even easier.

Lastly, you’ll need to handle this wire with utmost care. Regular and right maintenance can cause these wires to last for a lifetime. And, if you can maintain them, they won’t give up on you easily.


  • Works well on thicker metals. 
  • Can be used on different steels and coatings. 
  • Works well in windy weather. 
  • Easy to use. 
  • Has a deeper penetration. 
  • Affordable.


  • Can produce spatter. 
  • Struggles with thinner metals.

Our Winner

In the end, we fail to declare a winner between the two. This is because both of them have different purposes. And, you’ll need one to work on thicker metals and the other on thinner metals.


Q. What’s the main difference between 030 and 035 core wires?

Ans: Between the two, the main difference is the diameter. Also, the 030 wires work well with thinner metals. Whereas, the 035 wires work better with thicker metals.

Q. What’s the best core wire to use?

Ans: The Hobart Fabshield E71T-11 is the best core wire out there in the market.

Q. Can a flux core wire deteriorate over time? 

Ans: Yes, core wires aren’t constant. And, they can easily be damaged with moisture. Hence, maintenance of these wires is necessary for every step.

Parting Words

Well, that’s it from our end. Hopefully, you’ve understood the 030 vs 035 flux core wire comparison. Now, you can easily know what to expect from them.

Even though we couldn’t crown anyone the winner, you can adjust any of the wires. In the end, both of them arrive with decent penetration capability.

So, it depends on you and your needs. Good Luck!

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