WHY IS THERE NO AMPERAGE CONTROL ON A MIG WELDING POWER SOURCE

MIG welding power sources have what is known as a 'constant voltage' output
characteristic (Fig. 1). The arc voltage is established by setting the output voltage on the
power supply. The power source will then supply sufficient welding current to melt the
welding electrode at the rate required to maintain the preset voltage (or relative arc
length). This means that the wire feed speed can be used to control the welding current.

As the wire feed speed is increased, the arc length will momentarily become shorter so
the arc voltage becomes lower than the preset value. Because of its output
characteristic, the power source will supply a higher welding current. This increases the
melting rate of the electrode which self corrects the arc voltage and arc length.

The contact tip-to-workpiece distance affects the welding current too. Increasing the
contact tip-to-workpiece distance produces a longer electrode stickout, or electrode
extension. As the electrode extension increases, so does the electrical resistance of the
wire. Resistance heating causes the temperature of the electrode to rise. Therefore,
less welding current is required to melt the electrode at a given feed rate.

A long electrical stickout increases deposition rate because the wire is preheated before
melting in the arc. However, too long a stickout results in poor weld bead shape,
shallow penetration and an unstable arc. Good electrode extension is from 6 to 13mm
for short circuiting transfer and from 13 to 25mm for other types of metal transfer.