Because welding can be a significant fabrication activity for many companies, it is usually one of the first manufacturing processes to receive careful scrutiny when cost cutting is the goal. Unfortunately, many manufacturers think switching to a lower cost MIG wire will be the silver bullet to boost the balance sheet. In reality, an inferior MIG wire could translate into additional dollars spent in pre and post-weld operations such as cutting, forming, surface and joint preparation, pre-heating, cleaning, tacking, grinding and painting.

In fact, when examining the total cost of welding, the cost of the wire is often as low as approximately four per cent of actual welding costs, while the bulk of costs are overhead and labour. So, saving a penny on the price of the wire in the end may actually cost a company much more in productivity-robbing activities that otherwise could be avoided.
Selecting a quality MIG wire is critical. It can be more forgiving and produce a sound weld even under less than perfect conditions. Take, for instance, a plate with surface contaminants. The right MIG wire for that application may make some pre-welding operations obsolete. And, as more companies move to robotics, a quality MIG wire will provide accuracy in wire placement and consistency in the weld, making rework less of an issue.