Can You Use Welding Cable for Battery Cable?

The ability to weld is a necessary skill for many different trades. Welding cable has been used in the construction industry, automotive repair, and even welding schools. So what about using welding cable for battery cables?

However, while some people might think you can use it for battery cables, this isn’t always the case. Here’s why:

Can welding cable be used for battery cable? This is one of the most frequent questions for some people.  In relation to that, the answer is yes, welding cable can be used as a substitute for battery cables if you are on a budget or just don’t want to go out of your way to find it. There are some important things that you should know before deciding to use a welding cable, though.

The insulation on the welding cable has a different thickness than the battery cable and doesn’t have the same electrical properties. The insulation isn’t very flexible either, which is a bad thing for battery cables since they need to be able to bend and flex.

Welding Cable Size Chart

AWG Conductor Stranding Insulation Thickness (AWG) Nominal Overall Diameter (inches) Approximate Weight (Lbs./1000 ft) Ampacity of Conductor (Amps)
6 19/.0127 45 0.400 50.0 65
4 30/.0090 55 0.465 78.0 85
2 30/.0120 65 0.540 100.0 105
1 30/.0150 75 0.605 125.0 115
1/0 30/.0180 85 0.670 150.0 125
2/0 30/.0240 95 0.725 175.0 135
3/0 30/.0265 105 0.795 200.0 145
4/0 30/.0320 115 0.875 235.0 155
250 30/.0360 125 0.925 260.0 165
300 30/.0450 135 1.040 315.0 175
350 30/.0490 145 1.090 360.0 185
400 30/.0530 155 1.140 405.0 195
500 30/.0620 165 1.250 500.0 205
600 30/.0710 175 1.355 595.0 215
700 30/.0790 185 1.460 690.0 225
750 27/.0880 195 1.500 750.0 235
800 27/.0960 205 1.550 800.0 245
900 27/.1080 215 1.670 895.0 255
1000 27/.1200 225 1.785 990.0 265

What’s the difference between the battery cable and welding cable?

Welding cable is designed to carry much higher voltage ratings and is thicker than battery cables. While battery cables are largely for power that is used in vehicles.

A welding cable is a portable cord with an annealed bare copper conductor that can be moved from place to place for use as needed. Welding wire typically has many strands of fine copper wires wrapped in insulation, making it versatile and flexible enough when handled correctly.

A battery cable is a cable that is used to deliver current from a power source, such as a battery or generator. The cables have different resistance levels and thicknesses which can affect the voltage drop.

The main difference between welding cable and battery cable has to do with how much electricity they are designed to carry without overheating or breaking down. Welding wire is built to carry very high amperage, while battery cable is designed for use at much lower currents.

A welding cable can be used to run power from a generator or transport it in the back of an electric vehicle during work hours before being plugged into your home’s electrical system when you get off work.

Battery cables are used to carry current from the battery in a vehicle over relatively short distances. These cables have much thinner conductors, which means they can handle less amperage than welding cables without overheating or breaking down.

What gauge wire is used for battery cables?

When you are wiring something that will be drawing a lot of current, like an electric motor or starter, it is important to use the correct size wire. The larger the number in the gauge indicates how small and lightweight the cable is.

There are a variety of different wire gauges for different uses. Battery cables, at their widest point, should be between 8 and 14 gauge. On average, they’re considered 12-14 gauge so that they’ll hold up better during maintenance of cars, trucks, farm equipment, and other electric vehicles. A little thicker than regular wiring found in walls or homes, so it’s got a more substantial feel – not too heavy, though. Anything heavier can lead to a voltage drop on an engine. Just make sure you have a well-put-together power system when installing your vehicle wiring system – measure twice before cutting once. It will save you a lot of time and headache.

Can you use aluminum wire for battery cables?

Aluminum wire is an excellent choice for battery cables because it has a high conductivity ratio and can be used in applications that must run at very low temperatures without experiencing resistance issues or depleting the energy potential of your equipment. Aluminum wire is also an excellent choice if you need to make your own battery cables. However, even though aluminum wire has many positive characteristics, it isn’t suitable for every application.

One drawback that needs to be considered when using aluminum wire for battery cables is oxidation. Aluminum oxide formations can cause a substantial resistance in an electrical circuit if they are not properly dealt with through special insulation methods. This problem may become very serious over time, and aluminum wire should not be used if oxidation will become a problem.

 Is it safe to use welding leads with exposed wire?

You can use welding leads for other purposes, but use great care when doing so. You must take safety precautions and should not leave the exposed wire lying around where it could be a tripping hazard, or someone might handle it while they are unaware of its conductive nature. Anytime you have bare wires sticking out from any type of cord, there is a risk that someone will get shocked or electrocuted if they touch them.

The important thing to remember when using welding leads for purposes other than their intended purpose is safety precautions need to be taken, and the exposed wire should be treated immediately.


You can use a welding cable for battery cables. However, you should not do this unless it is the only option available to you. Welding cable does not have a high enough current capacity and will cause problems with your vehicle’s electrical system over time due to overheating of the wire insulation layer material. For best results, follow the manual. It is also best to check your mechanic if unsure about the safety of wiring for your specific vehicle. This way, you can ensure that the welding cable you are using is safe for your battery cables. The right cables attached to your battery will ensure that you have a long-lasting, reliable power source.

About the author, Phil Borges

Phil Borges is a battery aficionado. He's written extensively about batteries, and he loves nothing more than discussing the latest innovations in the industry. He has a deep understanding of how batteries work, and he's always on the lookout for new ways to improve their performance.