Blue Demon ER70S6.045 in 33 LB MIG Welding Wire - Low Spatter

In this review the Blue Demon ER70S6.045 in 33 LB welding wire is examined for shop users and home fabricators who need a reliable feedstock for carbon steel MIG/GMAW work. The bottom line: it is best for projects that demand strong, porosity-free welds and tolerance for imperfect fit-up. The reviewer found it produces consistently high tensile, x-ray quality welds when used with the required CO2 or CO2 mix shielding gas, and it performs well on castings, forgings and general repair work where low spatter and sound weld metal matter.

Key Features

• Porosity-free welds: Formulated to deliver porosity-free, x-ray quality weld deposits for structurally sound joints.
• High tensile strength: Provides the highest tensile strength (as welded) among plain carbon steel wires for durable repairs and parts.
• Low spatter: Engineered for low spatter during MIG/GMAW to reduce cleanup and improve weld appearance.
• All-position use: Suitable for welding in multiple positions, making it versatile for different fixture setups and fabrications.
• Good for rough fit-up: Commonly used for general shop applications where fit-up is poor, simplifying salvage and repair work.
• Gas requirement: Requires a shielding gas such as CO2 or a CO2 mix to achieve rated performance and deposit quality.

Who It's For

The wire is aimed at professional welders, maintenance shops and serious hobbyists who need a robust plain carbon steel filler that tolerates imperfect joint fit-up and offers high tensile strength. It is particularly useful for salvaging steel castings and forgings, or for general shop projects where structural integrity is a priority.

Those who should look elsewhere include fabricators who must weld without any external shielding gas or who need specialty alloy or stainless filler metals; this product specifically requires CO2 or a CO2 mix and is formulated for plain carbon steel applications only.

Pros & Cons

Pros

• Delivers porosity-free, x-ray quality welds that suit structural and repair work.
• High as-welded tensile strength compared with other plain carbon wires, increasing part durability.
• Low spatter formulation reduces post-weld cleanup and improves finish.
• Versatile all-position capability makes it useful across many shop tasks.

Cons

• Requires shielding gas (CO2 or CO2 mix), so it is not suitable for gasless or flux-cored workflows.
• Not intended for stainless or non-ferrous metals, limiting cross-material use.

Specifications

Product name	Blue Demon ER70S6.045 in 33 LB MIG/GMAW Welding Wire
Wire diameter	.045 in
Net weight	33 LB
Filler classification	ER70S6 plain carbon steel
Weld quality	Porosity-free, x-ray quality welds
Application	General shop, castings, forging salvage, home projects
Shielding gas	Requires CO2 or CO2 mix

Our Verdict

The Blue Demon ER70S6.045 in 33 LB wire is a practical, value-oriented choice for welders who need strong, low-spatter deposits on plain carbon steel and who can use shielding gas. It excels in repair, salvage and general shop use thanks to its porosity-free, high tensile welds and all-position capability, making it a good buy for shops and dedicated hobbyists who prioritize weld quality.

Frequently Asked Questions

Can this wire be used without shielding gas?
No. This wire requires a shielding gas such as CO2 or a CO2 mix to produce the intended porosity-free, x-ray quality welds.

Is this wire suitable for welding stainless or aluminum?
No. ER70S6 is a plain carbon steel wire formulated for carbon steel; use dedicated stainless or aluminum filler metals for those substrates.

Is it good for home projects?
Yes. The wire is noted as great for home projects, provided the user has access to the required CO2 or CO2 mix shielding gas.