ACUWELD MIG &TIG Welding Wires

ACUWELD Welding Consumables – MIG & TIG WIRES
ACUWELD is a very popular brand in Eastern Zone for MIG/MAG and Submerged Arc
Welding Wire for numerous welding applications. Having Production capacity of more than
10,000 MT of Welding Wires, which makes it one of the largest manufacturer of Eastern
India..
Products summary
ACUWELD MIG WIRE- MODEL/VARIANT-1.60mm,1.20mm,1.00mm,0.80mm
TECHNICAL SPECIFICATION- AWS SFA5.18
MIG welding wire consists of a spooled-up electrode that’s fed through a MIG welding “gun”
and is heated to melt metal and join workpieces together.
There are two primary types of MIG welding wire – flux-core and solid MIG welding
wire.
Flux-core wire is a metal electrode that contains a “flux compound” inside the electrode.
When the wire melts and reacts with the welding arc, this forms a gas that protects the weld
from oxygen, which can cause defects in the weld. This means that no shielding gas is
required for this type of wire – though in some cases, shielding gas may be used alongside
flux-core wire for even more protection.
In contrast, solid wire electrodes are exactly what they sound like – large reels of solid metal
wire that do not contain any flux. This means they must be used with a shielding gas. The
most common shielding gas is 75% argon and 25% carbon dioxide. The welding gun delivers
a steady stream of gas from a container, which surrounds the electrode and weld area to
prevent oxidation and defects in the weld.
Depending on the application, both kinds of MIG welding wire (solid and flux-core) can be
made from a variety of materials including aluminum, stainless steel, copper, and silver, to
name just a few .Our wires strictly conform to the standards and specifications of the
American Welding Society (AWS). AWS A5.18/A5.18M:2005.
ACUWELD TIG WIRE- MODEL/VARIANT- E308L, 309L, 316L, 202

TECHNICAL SPECIFICATION- AWS SFA 5.4
Gas Tungsten Arc Welding (GTAW) or otherwise referred to as Tungsten Inert Gas (TIG)
welding has versatile applications and produces weld quality of high standards. In fact, a
precise job can be easily carried out by a skilled welder with the help of a TIG welding
machine. We provide customized packing and packaging of TIG wires.
Our wires strictly conform to the standards and specifications of the American Welding
Society (AWS). SFA 5.4 identical with AWS specifications A5.4-92.
Acuweld- Copper coated filler wire(AWS ER70S-6) suited for general purpose and manual
welding applications in most industries. It is manufactured under BEMCO Quality control
programme and meets AWS Standards.
Acuweld aw 70- Copper Coated Filler Wire having deoxidants such as Mn & Si content.
Smooth flow gives shiny bead under optimum welding conditions in automatic and semi-
automatic welding. The deposited weld metal meet X-Rasy/Radiographic quality code
requirement.
Submerged Arc Welding Wire-Submerged Arc Welding Wire designed to be paired to meet
any industry specific welding requirement. Over 150 combinations are available for single
and multiple pass welding in both automatic and semi-automatic applications.
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Key Product features

 C-Mn steel solid wire
 Can be used with 100% CO2, Ar+CO2
 Uniform copper coating
 Radiographic quality weld
 Higher level of de-oxidisers make it suitable for application where dust, rust or mill
scale is present.
 Smooth wire feeding
Applications
 Earth moving equipment’s
 Rail wagon and Bogies repair and construction
 Manufacturing of LPG Cylinder and Pressure vessels.
 Auto components and sheet metal works
 Ship Building
 General and Heavy Fabrication
Products specifications
PRODUCT NAME
ACUWELD MIG WIRE
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MODEL/VARIANT-
1.60mm,1.20mm,1.00mm,0.80mm
TECHNICAL SPECIFICATION AWS SFA5.18
NO OF PHASE 3 PHASE
FREQUENCY 50H2
PRODUCT NAME
ACUWELD MIG WIRE
MODEL/VARIANT-
1.60mm,1.20mm,1.00mm,0.80mm
Page 3 of 38
TECHNICAL SPECIFICATION-
AWS SFA5.18
NO OF PHASE 3 PHASE
FREQUENCY 50H2
PRODUCT NAME
ACUWELD TIG WIRE
MODEL/VARIANT-
Page 4 of 38
E308L, 309L, 316L, 202
TECHNICAL SPECIFICATION- AWS SFA 5.4
NO OF PHASE- 3 PHASE
FREQUENCY-50H2
Acuweld
Copper coated filler wire(AWS ER70S-6) suited for general purpose and
manual welding applications in most industries. It is manufactured under
BEMCO Quality control programme and meets AWS Standards
Weld Metal Analysis in %
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Cu,Including Cu in
C Min Si S P
Coating
0.06- 1.400- 0.80- 0.025 0.030
0.50 Max
0.15 01.85 1.15 Max Max
Tensile Strength (N/mm2)—500-620
Yield Strength (N/mm2)—400-510
Elongation %--24-30
Acuweld aw 70
Copper Coated Filler Wire having deoxidants such as Mn & Si content. Smooth
flow gives shiny bead under optimum welding conditions in automatic and
semi- automatic welding. The deposited weld metal meet X-Rasy/Radiographic
quality code requirement.
Weld Metal Analysis in %
C Min Si S P Cu,Including Cu in Coating

0.06-0.14 1.40-1.60 0.80-1.0 0.025 Max 0.025 Max 0.50 Max
As Welded GMAW 100% CO2
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Yield Strength- 420MPa Min.
Tensile Strength- 500-640 MPa
Elongation in 2”- 24% Min.
Submerged Arc Welding Wire
Submerged Arc Welding Wire designed to be paired to meet any industry

specific welding requirement. Over 150 combinations are available for single
and multiple pass welding in both automatic and semi-automatic applications.
Submerged Arc Welding Wire Analysis in %
Wire Composition
Brand Conformance
C% Mn% Si% S%(max) P%(max) Mo%
ACUWELD 0.10 0.25 - 0.07
AWS 5.17 EL8 0.030 0.030 --
EL8 max 0.60 max
ACUWELD AWS 5.17 0.05 - 0.80 - 0.10 -
0.030 0.030 --
EM12K EM12K 0.15 1.25 0.35
ACUWELD AWS 5.17 010 - 1.70 - 0.10 0.030 0.030 --
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Wire Composition
Brand Conformance
C% Mn% Si% S%(max) P%(max) Mo%
EH14 EH14 0.20 2.20 max
ACUWELD AWS 5.17 0.05 - 0.95 - 0.20 0.45 -
0.025 0.025
EA2 EA2 0.17 1.35 max 0.65
STANDARD SIZES : Wire Diameter
mm 1.6 2.0 2.4 3.2 4.0 4.8

inches 0.062 0.078 0.094 0.125 0.156 0.188
Pallet packing
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Chemical Composition of Copper Coated Welding Wire

Grade CHEMICAL COMPOSITION OF COPPER COATED TIG/MIG AS PER AWS A5.18
C % Cr % Ni % Mo % Mn % Si% P% S% V% Cu% Ti Zr Al
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AWS ER- 0.06- 0.15 1.40- 0.80- 0.03

0.15 0.15 0.025 0.035 0.50 ---- ---- -----
70S6 0.15 1.85 1.15
AWS ER- 0.15 0.90- 0.40- 0.03 0.05- 0.02- 0.05-

0.07 0.15 0.15 0.025 0.035 0.50
70S2 1.40 0.70 0.15 0.12 0.15
AWS ER- 0.06- 0.15 0.90- 0.45- 0.03

0.15 0.15 0.025 0.035 0.50 ----- ---- ----
70S3 0.15 0.15 0.75
Grade CHEMICAL COMPOSITION OF COPPER COATED SAW WIRE AS PER AWS A5.23
C % Cr % Ni % Mo % Mn % Si% P% S% Fe% Cu% Al Amount
AWS EA2 0.05-0.17 -- -- 0.45-0.65 0.95-1.35 0.20 0.025 0.025 --- 0.35 -- --- ---
AWS EA3 0.05-0.17 --- --- 0.40-0.65 0.65-2.20 0.20 0.025 0.025 --- 0.35 -- --- ---
MIG Welding guide

GUIDE TO MIG WELDING
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This is a free basic guide on how to weld using a metal inert gas (MIG) welder. MIG welding
is the process of using electricity to melt and join pieces of metal together. MIG welding is
generally regarded as one of the easiest type of welding to learn.
Welding is a skill that needs to be developed over time, with a piece of metal in front of you
suitable protection and a welding torch in your hands.
WHAT IS MIG WELDING?

MIG welding was developed in the 1940's and 60 years later the general principle is still very
much the same. MIG welding uses an arc of electricity to create a short circuit between a
continuously fed anode (+ the wire-fed welding torch) and a cathode ( - the metal being
welded)
The heat produced by the short circuit, along with a non-reactive (hence inert) gas locally
melts the metal and allows them to mix together. Once the heat is removed, the metal begins
to cool and solidify, and forms a new piece of fused metal.
A few years ago the full name - Metal Inert Gas (MIG) welding was changed to Gas Metal
Arc Welding (GMAW) but if you call it that most people won't know what the you are
talking about - the name MIG welding has certainly stuck.
MIG welding is useful because you can use it to weld many different types of metals: carbon
steel, stainless steel, aluminium, magnesium, copper, nickel, silicon bronze and other alloys.
Here are some advantages to MIG welding:
 The ability to join a wide range of metals and thicknesses

 All-position welding capability
 A good weld bead
 A minimum of weld splatter
 Easy to learn
 Here are some disadvantages of MIG welding:
 MIG welding can only be used on thin to medium thick metals
The use of an inert gas makes this type of welding less portable than arc welding which
requires no external source of shielding gas. Produces a less controlled weld as compared to
TIG (Tungsten Inert Gas Welding)
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MIG welding Advantages and

Disadvantages
MIG welding is arguably the easiest of the arc welding processes for a novice welder – and
one of the most versatile for a skilled professional, whether you're working in automotive
chassis construction or container fabrication. But what are the headline advantages and
disadvantages of MIG welding. Grab a coffee, break open your biscuits of choice, and take a
few minutes to read the R-Tech take on what MIG is good – and not so good – for.
Since its introduction in the Californian aerospace industry in the 1940s, MIG welding has
grown and grown in popularity. As well as the technique’s suitability for metals such s
aluminium and magnesium, this is largely due to MIG welding’s speed and relative ease.
Which leads us perfectly into the first of MIG welding's advantages.

The advantages of MIG welding

MIG welding is fast
With any welding, the time taken has to reflect the difficulty of the join and the quality
desired from the finished weld. But, all things being equal, if you put MIG welding up
against the other popular forms of welding, MIG is going to win most if the time – whether in
the hands of a welding novice or a seasoned fabrication specialist. Why? The answer lies
primarily in the continuously-fed electrode, which may be fed from the welding machine,
from a spool-gun MIG torch, or in sophisticated industrial applications, through a
combination of push and pull feed technology.
Ease of use
One day, we’ll find out just how easy MIG welding is for a complete novice when we set our
copywriter loose on some gash plate with one of our machines. He had a go at oxyfuel
welding about 40 years ago, so if anyone counts as a novice, it’s probably Al. Watch out for
the video and blog post in future…
But seriously, the one-handed operation of the MIG torch and the automation of several other
aspects, make MIG welding easier to learn and gain proficiency with than, say, TIG welding
or stick welding.
MIG weld quality
Put simply, all things being equal, MIG welding allows you to quickly make very high-
quality welds – often faster than other welding techniques. As we’ll mention again later, MIG
is flux-free, so there’s no chance of entrapping slag in the weld. Result? Great welds and
fast…
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Long-pass welding
Here’s another reason why MIG scores for speed. You’re able to deposit more weld metal
with each pass of the MIG torch. Maybe that’s less of an advantage on a small weld, but
when you have a long, complex weld to make, you can get the job done with fewer passes –
which saves time, helps you work more efficiently and (if you’re a welding professional)
helps you work more profitably. That’s definitely good.
Penetration matters
Of course it does, and with MIG you can get great penetration (the depth of your weld) and
be sure of a strong, smooth, bead. Best of all, you can achieve this on a wide range of metals
with differing thicknesses. Aluminium? No problem. Mild steel? A cinch? Magnesium? No
worries. All you have to do is get your head around setting the correct current (Amperage) for
the wire and the metal and great penetration will follow.
Fewer stops and starts
That continuously-fed MIG electrode scores again when it comes to cutting down the number
of times you have to stop and start welding during a job. With stick welding, or even TIG,
you’ll be stopping and starting as if you are in rush-hour traffic. What’s more, there will
inevitably be adjustments to make and new electrodes to fit before you can re-start that weld.
Just like the difference between trying to get to a job at peak time and making the same
journey early in the morning, it all adds up. Try it and you’ll see what we mean.
Electrode stub loss? What’s that?
If you’ve ever tried stick welding, you’ll know that no matter how skilled you are, you end up
wasting several centimetres of each welding stick. It’s called stub loss, but it’s a term you can
banish from your welding vocabulary with MIG welding. That’s because you can use all your
continuously-fed electrode. That’s more time and money saved!
MIG works with many metals or alloys

It’s true. Remember how MIG was originally developed for aluminium and magnesium
alloys used in Californian aircraft factories? That same versatility means that MIG works a
treat with alloys, stainless steel, aluminium and mild steel alike. A wide range of filler
materials means increased precision when matching filler to the workpiece metal or alloy.
MIG welding is clean
Okay, so maybe TIG welding is the ‘King of Clean’ when it comes to electric arc welding,
but MIG isn’t that far behind and it makes traditional stick welding look positively ‘scuzzy’.
It’s true. Unlike stick welding, which is renowned for the flux involved and the amount of
slag generated, MIG welding is really rather mess-free. Because there’s no flux, you can’t
trap slag in your weld – it’s another key to those high-quality welds we mentioned earlier.
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What’s more, because you’ve got that protective gas shield (typically argon or an argon mix),
there’s minimal loss of alloying elements – and the tiniest amount of weld spattering.
That’s good, right? Less clean-up time, neater jobs, faster, and more productivity. Result!
If you’re a seasoned MIG welding pro, none of this will surprise you. But if you’re a welding
newbie, it should be reassuring. But surely there’s a catch? There’s always a catch, right?
Okay, like most things in life, there are two sides to MIG and we’d be remiss if we didn’t flag
up the known limitations of this welding method.
Disadvantages of MIG welding

Compared to stick welding, a basic MIG welding set up will cost you more, so it’s arguable
that MIG welding is more expensive to get into.
MIG welding costs more (to set up)
The thing is, that a good MIG welding machine will last you years and years; and if it’s
designed for repair and maintenance at component level you won’t end up having to replace
the whole machine after a few years when all you need is a new part. So, a good MIG
welding machine is an investment. And there’s more, because with many modern machines,
you can do stick welding (maybe even TIG welding too) with the same machine. That gives
you welding power that sticks can never give you – and opens up more opportunities as you
develop your skills. By the way, if you haven’t looked recently, you should check out the
spec of a MIG welding machine that you can invest in for just a few hundred pounds like our
R-Tech MIG 180 MIG Welder. Prepare to be impressed and amazed. You can get a lot of
machine for the price of a long weekend away…
More maintenance?
Okay, a MIG welding machine is more complex than a stick-welding set up and regular
maintenance is importance, for safety and quality of welding. But remember again our point
about component-level repair and maintenance. Not all machines allow this (R-Tech MIG
welders do), but many do. As well as that, if you choose right, your welding machine supplier
will lend you a MIG welder while yours is in for a service. We do! Why wouldn’t you?
The wind problem
Not that kind of wind problem, but the effect of draughts or wind gusts on the shielding gas
flow if your workshop is badly sealed or you are trying to work in the middle of a field.
Okay, hands-up, it can be an issue. But decent welding screens are easy to construct – or buy
off the shelf – and they will make a big difference in all but serious gale-force conditions.
It’s something to be aware of, but it’s not insurmountable…
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Portability
Traditionally, MIG welding has lost points due to the lack of portability of MIG welding
machines. There’s truth in this; your average MIG welder isn’t the most portable bit of kit
you’ll own. But modern machines are remarkably portable. Take the R-Tech 180 Amp
Portable Inverter MIG Welder (240v), which weighs in at 330 x 210 x410 mm. Even with a
generator (we can help there too) and gas, we’re sure you’ll agree that’s pretty compact…
Unless you are out on the road day-in-day-out, maybe portability isn’t the big MIG welding
disadvantage that it’s made out to be.
The other thing that is sometimes tied-in with portability is the size of your typical Euro MIG
torch. Maybe in the trickiest, tightest, corners if you’re trying to do a complicated weld, a
MIG torch might be a little cumbersome. But most of the time? We think not. You should try
one of the latest MIG torches yourself to see…
Weird positions
If that tricky weld happens to include vertical or overhead welding, the high heat input and
mobility of the weld puddle may mean that you need to look at another welding technique.
But that’s a small price to pay for all the advantages of MIG welding. Besides, if you choose
the right machine, you’ll have stick-welding capability anyway. Problem solved!
Burn-through
With certain materials, not least aluminium, there is a risk of burn-through if your workpiece
is less than .5mm. Up to a point, your skill level may help you get around this, but it's
generally accepted that MIG isn’t best suited to very thin materials.
So there you have it. The pros (many) and cons (a few, and often surmountable) of MIG
welding in the time it takes to down that coffee and polish off a few (is half-a-packet a few)
biscuits.
If you’re in the market for a new MIG welder, check out our collection here at R-Tech, or if
you fancy getting some free advice on what machine spec is best suited to your needs, give
our technical team a call for free on 01452 733933. They’d be more than happy to offer their
advice!
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What are MIG wires used for?

MIG welding (metal inert gas welding) is one of several welding processes that use electricity
to melt and join pieces of metal. MIG welding uses lots of electricity to create an electrical
arc between an electrode wire and the metal being welded. The arc melts the wire, which is
then deposited to create the weld. When the heat is removed, the weld pool cools, solidifies and
form a new piece of fused metal – the weld is complete. All this happens at the nozzle of a MIG
torch, a hand-held device not unlike a fuel-filler nozzle that simultaneously feeds electrode wire and
inert shielding gas to the weld.
What MIG is better for?

MIG welding (and the new generation of affordable MIG welding equipment) is best suited
to smaller, relatively lower-volume work, mainly manual welding that takes place in and
around factories and metal working workshops where the vulnerability of MIG to draughts is
less of an issue.
When you are fabricating small structures or repairing customers’ cars, speed, weld quality
and high productivity are the keys. And that’s where MIG comes into its own. Similarly, for
hobby-welders working on weekend projects in garage or garden shed, or novice welders
who need good welding capability without the steeper learning curve of TIG or traditional
(and cumbersome) oxyfuel welding.
Throw in MIG welding’s renowned cleanliness, long-pass capability, applicability to metals

and alloys as diverse as mild steel, stainless steel, aluminium and magnesium, and it’s easy to
see why this welding process has become the darling of small and medium-sized industry.
Where MIG isn’t so good?

No welding technique is perfect for all welding applications, and MIG is no exception. The
classic exemplar of MIG’s disadvantages would be an agricultural or construction application
where welding has to take place on-site, in the middle of an exposed field, where the wind is
blowing. True, windshields can make things a bit easier, but generally, MIG welding is better
suited to the more controlled environment of an enclosed factory or welding shop
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MIG welding disadvantages

Here’s a summary of the characteristics that are usually held up as MIG disadvantages:
 MIG welding set up costs

 Maintenance
 Wind problems
 Portability
 Weird positions
 Burn through
What is better TIG or MIG welding?

This is the question among electric arc welders and those who rely on their skills. Both MIG
and TIG (tungsten inert gas) welding are powerful, versatile, tools that have been refined,
since the 1940s, to their current advanced capability.
The major difference between MIG and TIG is that MIG welding uses a continuously-fed
electrode wire that emerges from a MIG handset, while TIG welding combines the non-
consumable tungsten electrode in the TIG torch with a hand-held, consumable, welding rod.
The TIG welding rod is held in the welder’s other hand and carefully fed into the weld
puddle. Welding power for the TIG process is usually controlled by a foot pedal. Imagine that
childhood game of rubbing your tummy while patting the top of your head. Okay, now try
tapping your left foot at the same time…
Advantages of MIG over TIG

welding?
From the description above, you probably get a feel for the complexity of TIG welding, and
the skills required to master it. It’s what underpins many of the differences between the two
processes. So what are the main differences between MIG and TIG?
 All things being equal, MIG is easier to learn.

 MIG is generally faster.
 It’s good for larger jobs that need long-pass welds.
 MIG is often more effective with thicker metals.
 MIG welders often cost less than TIG welders.
 MIG is arguably more accurate. The continuous nature of MIG welding reduces the
possibility of flawed welds.
 MIG welding is better for longer production runs.
 MIG welds tend to be cleaner, with less post-weld cleaning required.
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Is gasless MIG welding any good?

It’s a good question, complicated by the misconception that ‘gasless MIG’ doesn’t use a gas.
Let’s put that one to rest first: all MIG welding uses a shielding gas to protect the weld
puddle and the tip of the electrode wire.
What ‘gasless MIG’ actually refers to is so-called ‘gasless MIG wire’, or ‘self-shielding’
MIG wire that originated in agricultural welding in North America. In its original bucolic
implementation, self-shielding MIG wire was used for in-the-field farm repairs – often in
working environments where the worksite was blasted by prairie winds and it was
inconvenient to carry around the normal MIG gas bottle.
And there’s the one advantage of so-called ‘gasless MIG’ – where all else fails, where a
windshield isn’t sufficient and that MIG weld must be made in the field, a product such as a
MIG all-positional, single-pass, flux-cored welding wire can make the difference. But, boy
does it smoke…
So that, in brief, is an introduction to what MIG welding is used for and why it gets chosen
over its welding-shop bedfellow, TIG welding.
Whether you weld racing car parts or you are making a small metal structure in your home
workshop, MIG is a relatively easy to use, fast, proven welding technique that will give you
great results with less of a learning curve than TIG.
Best of all, with modern MIG welding machines, it’s remarkably easy to get welding and
hear that satisfying ‘fried egg’ sizzle as your professional or amateur welding project takes
shape.
Page 18 of 38
MIG Welding Process
What is MIG welding?
Metal inert gas welding (MIG welding) is one of several welding techniques that use
electricity to melt and join pieces of metal. Since its invention in the early twentieth century,
the appeal of MIG welding has grown phenomenally based on its speed and ease of use –
even by newcomers to welding. Read on to learn more…
MIG welding is a sub-type of gas metal arc welding (GMAW), a process that’s been widely
used since 1948. Since then, despite equipment details changing quite a bit, and reference to
the process by various names (including gas metal arc welding, spray arc welding, flux-cored
arc welding and short-circuit welding) the general principles remain the same.
How MIG welding works

Whether you weld in your garden shed, a Formula 1 team’s workshop, or using production-
line robots in a massive factory, MIG welding works on the following principle. Using lots of
electricity, an electrical arc (a short circuit) is created between an electrode wire (a positive
anode) and the parent metal that’s being welded (a negative cathode). The arc melts the
electrode wire, which is then deposited to create the weld. When the heat is removed, the
weld pool cools, solidifies and form a new piece of fused metal – the weld is made.
When you use a modern MIG welding machine like ours, spool-fed electrode wire is fed
through a tensioning mechanism and into a co-axial supply line. This leads to a hand-held
MIG welding gun – the MIG welding torch or ‘gun’.
At the same time, a shielding gas (typically argon, carbon dioxide or a mixture) is fed along
the same supply line to the gun. The gas protects the weld pool from atmospheric gases that
would otherwise weaken the weld.
Avoiding common MIG welding defects

Robert White, R-Tech’s managing director says: ‘From experience, most problems you will
encounter with MIG welding will come down to one of four things. They are incomplete
penetration, excessive penetration, incomplete fusion and whiskers. In each case the solution
is pretty simple. To solve incomplete penetration, increase wire feed and reduce the amount
the wire protrudes from the MIG gun. To correct excessive penetration, reduce the size of the
gap you’re trying to fill. You can usually fix incomplete fusion by not allowing your
electrode wire to get in front of the weld pool. As for those whiskers? Keep your wire at the
front of the weld, make the weld pool smaller, and adjust the wire so it sticks out of the MIG
gun less. Of course, for more helpful advice on MIG welding, our team is always here for
you.’
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MIG welding is versatile

MIG welding is particularly versatile because you can use it to weld many different metals.
These include carbon steel, stainless steel, aluminium, magnesium, copper, nickel, silicon
bronze and other alloys.
Okay, so the MIG welding process isn’t the best choice for all welding jobs. But for a wide
range of professional and amateur welding, MIG is the best solution. Let’s have a chat about
your MIG welding challenge
As with any industrial process, MIG welding comes with advantages and disadvantages. The
good news – as millions of amateur and professional welders already know – is that for a vast
range of welding tasks, the advantages outweigh the disadvantages. Here are some of the
main ones:
Advantages of MIG welding

 MIG welding is fast. That’s mainly due to the continuously-fed electrode wire and the way it
reduces the amount of stopping and starting during welding jobs.
 It’s suitable for joining many different metals and metal thicknesses too. A characteristically
good weld bead and the ability to vary weld penetration by changing the amount of current
makes achieving strong, smooth welds remarkably easy.
 All-position welding capability: MIG welding handles horizontal, vertical or flat welding with
confidence.
 There’s minimal clean-up requirement. Only TIG welding is cleaner; compared to traditional
stick welding, MIG doesn’t use flux, or create extensive, messy weld spatter and slag.
 High-deposition MIG welding enables ‘long weld passes’ so you can deposit more metal with
each pass and use fewer passes to weld a large joint. The result? Faster welding and
increased productivity.
 Avoidance of waste: unlike stick welding, which typically wastes part of each electrode
(electrode stub loss), continuously-fed wire means you use all your electrode during MIG
welding.
 MIG welding is easy to learn, mainly thanks to the fact that several parts of the process are
automated.
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Disadvantages of MIG welding:

 MIG welding needs a bit more initial investment in equipment compared to traditional stick
welding. However, the specification, capability and reliability of today’s best MIG welding
machines is impressive. For serious professional or hobby welders, modern machines offer
great value for money.
 Higher maintenance of MIG welding equipment? With modern, reliable machines (and our
free loan machines), this argument needn’t apply.
 MIG welding can only be used on thin to medium-thick metals (typically between 0.6mm
and 14mm).
 There’s an argument that MIG welding is less portable than other welding processes that
don’t require an external gas source. This may be true sometimes, but compact modern MIG
welders often redress the balance. For lots of professional and amateur welding, MIG is the
preferred method.
 Compared to tungsten inert gas (TIG) welding, MIG welding may give less controlled welds
under some circumstances.
 Outdoor MIG welding can be more difficult because of the effect of wind on the shielding
gas. Then again, this can often be solved with higher gas pressure, portable wind breaks or
even gasless wire...
So there you have them, the main pros and cons of MIG welding. As you can see, modern
MIG welding equipment and thoughtful customer service details (such as free loan machines)
make some of the traditional ‘disadvantages’ much less of an issue
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TIG Welding guide
GUIDE TO TIG WELDING
This is a guide on how to do TIG welding
using a TIG welder (Tungsten Inert Gas)
TIG welding is a skill that needs to be developed over time, with a piece of metal in front of you and
with a welding torch in your hands. TIG welding requires patience and practice.
1. WHAT IS TIG WELDING?
 TIG Welding can be used to weld aluminium, copper, titanium etc… and even two
dissimilar metals. This process is ideally suited to handling tricky welds such as S-
Shapes, curves, corners or where the weld is going to be visible and where accuracy
and finish is important. TIG welding allows a greater variety of metals to be welded
than other forms of welding
 With superior arc and weld puddle control, TIG welding allows you to create clean
welds when appearances count. Because the heat input is often controlled by pressing
on a foot pedal, similar to driving a car, TIG welding allows you to heat up or cool
down the weld puddle giving you precise weld bead control. This makes TIG welding
ideal for cosmetic welds like sculptures, architectural and automotive welds
 The TIG welder generates heat via an arc of electricity jumping from a tungsten metal
electrode to the metal surface that you intend to weld – which is usually aluminium or
steel
 TIG stands for Tungsten Inert Gas – named from the tungsten electrode and the shield
of inert gas (Argon or argon mixture) surrounding it.
 A TIG welder needs a filler rod to provide the welding bead when joining two pieces
of metal together
 TIG welding produces no sparks or spatter because only the necessary amount of
filler metal is added to the welding pool.
 TIG welding produces no smoke and fumes unless the base metal contains
contaminants or has a dirty surface
 TIG welding doesn’t produce slag and requires no flux because the argon gas protects
the weld pool from contamination
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2. CHOOSING AND PREPARING THE TUNGSTEN ELECTRODE
A tungsten electrode is required when TIG welding and this is inserted into the welding
torch. This electrode carries the welding current to the work. For welding aluminium the
most popular choice is a Zirconiated TIG tungsten electrode (White tipped), for steel the
most popular is a Thoriated TIG tungsten electrode (Red Tip)
A number of tungsten alloys are also available (including Thoriated Tungsten)
There are different sizes of tungsten’s available which relate to the welding power you are
using for a particular job. It is important to use the correct size of electrode for the
welding power you are going to use. See below:
ELECTRODE

RATINGS
Electrode Diameter 2% Thoriated on Pure Tungsten on Zirconiated Tungsten on
(mm) DC (amps) DC (amps) AC (amps)
1.0 80 30 60
1.6 150 80 120
2.4 250 130 180
3.2 400 180 250
4.0 500 240 320
4.8 750 300 390
6.4 1000 400 525
Preparation of the tungsten electrode is important. The end needs to be ground to a point
Brand new electrodes will always need to be prepared in this way. When welding on
aluminium the tungsten will begin to form a ball, this is perfectly normal. When welding steel
the electrode will always stay pointed.
With the introduction of new power source technologies, the use of pure tungsten is
decreasing.
Pure tungsten melts at a lower temperature causing it to easily form a rounded ball at the tip.
When the ball grows too large, it interferes with your ability to see the weld puddle and
causes the arc to become unstable.
Ceriated tungsten can withstand higher temperatures and works very well with the new
squarewave and inverter machines for the following reasons:
 Holds a point longer and starts well at low amperages.

 Can be used on both AC and DC polarities. When welding aluminum, it has become
very acceptable to grind a point on ceriated tungsten (especially when welding on
thinner materials).
 Allows welding amperages to be increased by 25-30% compared to Pure tungsten of
the same diameter.
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TIG WELDING BASICS

What is TIG welding?
Tungsten inert gas welding (TIG welding) is another welding process that uses electricity to
melt and join pieces of metal. TIG welding was invented in the 1940s to meet the challenge of
welding magnesium and aluminium in the Californian aerospace industry. Since then, its
popularity has grown phenomenally. This is largely due to its versatility, cleanliness and
minimal finishing requirement. And its suitability for welding so many different metals. Read
on to learn more…
TIG welding (aka gas tungsten arc welding or GTAW) is a sub-type of gas metal arc welding
(GMAW). Although equipment details have evolved since its invention, the general
principles of TIG welding remain unchanged.
TIG welding isn’t the easiest welding technique to learn and master, nor is it the cheapest.
However, it will reward the effort you invest in mastering it. Make no mistake; the results
that can be achieved with TIG welding really are amazing.
How TIG welding works

TIG welding uses electricity to create an arc (a short circuit) between a non-consumable
tungsten electrode (a positive anode) and the metal being welded (a negative cathode). The
arc is shielded by a flow of inert gas, typically argon.
A non-consumable tungsten electrode
Unlike the consumable electrode wire in MIG welding, the high (c. 6192 °F or 3422 °C)
melting point of TIG welding tungsten electrodes means they won’t melt during welding.
Instead, the arc between the electrode and the work melts the parent metal. At the same time
(unless it’s an autogenous weld, such as a temporary tack weld), the arc also melts a separate
welding rod of filler metal to form the weld bead.
Inert shielding gas
Meanwhile, the molten weld pool is protected by an inert shielding gas. This is typically
argon or an argon mixture, although experienced TIG welders may use helium for faster
welding under certain circumstances.
The shielding gas is fed along a supply pipeline from the welding machine to the TIG torch
that holds the tungsten electrode. As with other forms of electric arc welding, when the heat
is removed, the weld pool cools, solidifies and forms a new piece of fused metal – the weld is
complete.
Because of this, when using a TIG welder, you need to co-ordinate interaction of a hand-held
TIG torch with a filler rod as well as varying the electrical current. Keeping the electrode the
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correct distance from the weld, holding the filler rod tip in position, keeping both in the
shielding gas and adjusting the current all add to TIG welding’s complexity.
The versatility of TIG welding

That same complexity helps make TIG Welding so versatile for welding a diverse range of
metals. Mild steel, stainless steel, aluminium, magnesium, copper alloys, titanium and gold
are all TIG weldable. Even dissimilar metals can be TIG welded – and all with minimal mess.
Ever since the early days at California’s Northrop Aircraft Corporation, TIG welding has
endeared itself to welders because of this versatility. And for its capability when handling
tricky welds such as ‘S’ shapes, curves and corners. Or anywhere that welds will be visible,
and where accuracy and finish are important – from a sports car chassis to your next DIY
welding project!
Ensuring quality TIG welds

R-Tech’s managing director, Robert White, says: ‘Years of experience working with
professional and amateur welders confirms that, of all the arc welding techniques, TIG
welding consistently gives the best combination of quality and finish. Okay, TIG isn’t quite
“plug-and-play-easy”, but it’s really worth investing time and effort to master. From the start
of your TIG welding, do get into the habit of keeping your workspace safe, clean and tidy,
and investing in clean, moisture-free, high-quality shielding gas from a reputable supplier.
Remember, too, the importance of keeping work dry, using clean, good-quality, filler rods,
and always keeping that shielding gas flowing while welding to avoid the porosity that ruins
welds. Of course, for more helpful advice on TIG welding, choosing equipment and
consumables, we’re always here for you.’
Pros and cons of TIG welding

As we keep saying, TIG welding is incredibly versatile and suitable for a wide range of
metals. However, as with any welding process, TIG welding has advantages and
disadvantages. Here are some of the main things to know when considering TIG welding:
Advantages of TIG welding
 TIG welding is suitable for widely-varying metal thicknesses. It is even suitable for very thin
materials that are difficult (or impossible) to join with other welding techniques.
 Superior arc and weld puddle (or ‘pool’) control delivers clean, attractive welds when
appearances count. Because heat input (determined by electrical current) is often controlled
with a foot pedal, TIG welding allows you to heat or cool the weld puddle for precise control
of the weld bead. This makes TIG welding ideal for cosmetic welds on sculptures,
architectural features and in automotive work.
 TIG welding is possible in any position: vertical; horizontal; overhead.
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 Minimal smoke and colourless shielding gas means it’s easy to see your workpiece while
welding.
 TIG welding is very clean, with less spatter, smoke, sparks or fumes than other welding
techniques. Because of this, TIG welding requires minimal cleaning or finishing, so you save
time and money.
 TIG welds are extremely ductile (less brittle), stronger and more corrosion resistant than
other welds.
 The best TIG welding machines also allow you to do traditional stick welding.
Disadvantages of TIG welding
 TIG welding is relatively slow, especially when you’re starting out. Even done by skilled TIG
welders, the process is often slower than other welding.
 Because of its complexity, TIG welding comes with a steeper learning curve than other
welding processes. As we keep saying, the rewards from mastering TIG welding are
considerable, but you will need to put the time in and be patient while developing your TIG
skills.
 Because it’s critical to maintain a constant flow of gas over the weld pool, TIG welding can be
very challenging outside the controlled (wind-free) environment of a workshop.
 Compared to basic stick welding machines, a good TIG welder is more expensive. However, if
you want to master TIG welding and reap its benefits, the investment in top quality kit,
consumables and accessories is worth it.
So there they are, the main pros and cons of TIG welding. We say, don’t let this put you off
investing in good-quality TIG equipment, practising hard and mastering the art and craft of
TIG welding. Of all welding processes, TIG welding remains the most versatile. It’s also the
one capable of delivering the neatest, highest quality, most impressive welds.
What’s the Difference Between MIG and

TIG Welding?
During MIG welding, a continuously-fed electrode wire and shielding gas feed into the
welding area via a hand-held MIG torch. With TIG welding, the torch holds a consumable
tungsten electrode and shielding gas is fed over this through a supply line. At the same time,
a hand-held filler rod is fed manually into the weld puddle while electrical current is varied
with a torch-mounted control or a foot pedal.
Is MIG or TIG welding better?

It all depends on what ‘better’ means to you and your welding project? Since introduction to
the US aerospace industry in the 1940s, what we now know as MIG and TIG welding have
evolved as staples of amateur and professional welding worldwide.
MIG welding is widely accepted as being simpler and easier to learn and master than TIG
welding. Because of its continuous feed, the MIG process is faster than TIG. What’s more,
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because MIG’s filler means you don’t have to heat the workpiece all the way through to form
the weld, it’s arguably better for thicker materials, including heavy structural elements.
Greater control and precision
Compare this to TIG welding’s greater control, precision and neatness, applicability to
welding in different positions and minimal requirement for finishing. Then there’s its
suitability for a very wide range of metals, including exotics. And for welding thinner-gauge
metals.
Ask a professional who’s used both processes and we’d wager they’ll say TIG welding is the
‘better’ process – followed shortly afterwards by the qualification that it all depends on the
job, thickness of the workpiece and time available... For welders fluent in both processes, one
of their greatest skills will be choosing between MIG and TIG for a given project.
What is the easiest welder to use?
It’s a fair generalisation that, for a novice with a given level of latent ability, MIG welding
will be easier to learn then TIG welding.
What is a TIG welder used for?
In terms of materials, TIG welders are great with steel, aluminium, copper and titanium to
name just a few. In terms of applications, TIG’s range is wide: motorsport; aerospace;
industrial fabrication; production line creation; containers; industrial structures; and much
more – particularly where very thin metal is used…
What is the best welder for a beginner?
There’s a very strong argument for stick welding being the best process for absolute
beginners to learn first – but we’re not talking stick welding here. So, when progressing to
MIG or TIG, there’s a strong consensus that it’s MIG.
As for the best MIG welding machine to buy? Talk to an experienced supplier with a long
track-record selling welding equipment and see what they suggest. In the case of UK-based
R-Tech Welding Equipment, it could easily be the popular R-Tech 180 Amp Portable
Inverter Mig Welder (240v) …
Is TIG stronger than MIG?
To offer a definitive answer here, going one way or another, is hard. You see, it all depends
on variables including the welding task, materials used, the welder’s skill, quality of set-up,
whether tensile strength or malleability is most important and the process used for that
particular project.
It’s probably true to say that TIG welding is inherently stronger. And that it will give stronger
welds in the hands of a skilled professional. Now qualify this by factoring in the greater skill
level required for good TIG welding. In that case, a less-skilled welder or an amateur is
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unlikely to get the best from TIG. In that situation, the strongest weld they’ll be able to
achieve might come from the simpler-to-learn-and-master MIG welding process.
Further reading on the strength of TIG and MIG welding
For an example of further reading on the strength of TIG and MIG welding with stainless
steel, read the 2017 paper by Assistant Professor Saurabh Kumar Khotiyan in The
International Journal of Advance Engineering and Research Development (IJAERD):
‘Comparison of Hardness and Tensile Strength of TIG and MIG Welding Using Stainless
Steel-202’ Interestingly, the paper concludes that ‘TIG is the best suitable welding process to
join Stainless Steel grade-202 as compared to MIG welding processes.’
Why would you use MIG welding?
For starters, there’s MIG welding’s relative simplicity, ease of learning if you’re just starting
welding, and suitability for materials such as aluminium, mild steel and stainless steel. As
mentioned earlier, it’s way faster than TIG welding. And if the signature ‘stacked coin’ TIG
finish isn’t a priority – or you’re happy with lots of manual finishing – it’s a very acceptable
welding process for many applications.
Given that MIG welding uses a continuously-fed filler wire, it’s also suitable for welding
moderately thin to thicker metals. It’s not that TIG welding can’t be used for heavier
welding, but that the TIG machine you’ll need will have to be very powerful indeed.
Aluminium Welding (MIG and TIG)

Can you weld aluminium? Yes you can, but if you ask any welder which materials are most
challenging they’ll probably mention this one. Fortunately, applying a few tips, tricks and
guidelines makes aluminium welding even easier to master. So what does the R-Tech
Welding Equipment team suggest? Read on to find out…
But first, a few words on the challenge of working with aluminium. Not surprisingly, it’s
aluminium’s inherent characteristics that create the biggest test for welders.
Why is welding aluminium difficult?
Aluminium is a good thermal conductor that disperses heat quickly, which can easily lead to
unwanted workpiece distortion or cracking. Furthermore, aluminium is renowned for its
vulnerability to ‘blow through’ – where the metal just melts away under an over-powerful
arc. Aluminium also oxidises very quickly when exposed to the atmosphere. This gives
aluminium its renowned ability to resist corrosion, but it also means your aluminium
workpiece will need thorough cleaning before you strike an arc and weld. And, as R-Tech’s
Mike Gadsby explains, ‘the colour of aluminium can even make it hard to see if it’s ready to
weld, particularly with the TIG process.’
What welder do you use for aluminium?
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Almost exclusively, it will be a MIG or TIG machine. You’ll find a couple of machine
suggestions later, but now let’s move on to that guidance. Let’s start with MIG welding
aluminium.
MIG welding aluminium

Can you use a MIG welder on aluminium?
Absolutely! So here’s some useful advice for MIG welding aluminium. Naturally, it’s a high-
level summary. For more detail, research further or seek advice from reliable sources such as
Mike and his R-Tech colleagues. There isn’t much they haven’t seen regarding MIG welding
aluminium. Mike adds: ‘MIG welding aluminium may not be the easiest process to set up, or
the most accurate. But it’s a fast, valuable addition to any MIG welder’s skills.’
 When choosing electrode tips for MIG welding aluminium, make sure they’re specifically
designed (Al-marked) for this versatile material.
 Make sure your welding machine and wire-feed mechanism is correct for aluminium
welding. This includes fitting a Teflon liner and U-groove rollers. Or by using a dedicated
aluminium spool gun to minimise the length of electrode wire being driven. It might also
involve – normally only for intensive professional use – using a push-pull MIG torch for
super-precise wire delivery. However, do be aware that not all MIG welding machines work
with a dedicated aluminium spool gun – look at R-Tech’s MIG 180, PRO MIG 250 and MTS
255 to see some machines that do. By the way, although the R-Tech MTS 450 doesn’t take a
spool gun, it has a very good four-roller wire-feed system that can be fitted with U-grooved
rollers that grip aluminium wire firmly.
 Moving from the welding machine cabinet to the MIG torch, do make sure that your torch is
in good condition. If you’re planning lots of aluminium MIG welding, you might consider a
larger-sized torch. Why? Because the greater heat generated by welding aluminium can
overwhelm a low-capacity torch. With aluminium, it’s always good to have power in hand…
 Now think back to how aluminium oxidises, and the different thermal properties of
aluminium and those oxides. It’s vital to clean your aluminium workpieces thoroughly before
welding. Use a stainless-steel wire brush that’s only used on aluminium, brush in one
direction only, and be careful not to work the oxide layer into the material. If the
aluminium’s surface is oily, use a good degreaser.
 As with all MIG welding, make sure to choose the correct wire for the grade of material (in
this case aluminium) that you’re welding.
 Due to its thermal properties, aluminium is very prone to distortion. Minimise the risks by
tack welding or clamping the joint to prevent movement or distortion as you weld.
 If you’re welding particularly thin aluminium, consider using a brass or copper backing plate
behind your work. It helps avoid the blow through that aluminium is so susceptible to.
Welding with a fast travel speed is another way to prevent blow through – and distortion.
 Stop and start as little as you can. To avoid porosity or voids when MIG welding aluminium,
weld in one pass wherever possible. Because aluminium’s notoriously cold to start with, it
needs to get up to temperature and stay there – hence the importance of that single pass if
you want to avoid undesirable cold-lapping.
What gas do you use for MIG welding aluminium?
Typically, it’s pure argon run at a gas-flow rate of around 14–16 LPM.
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TIG welding aluminium

As with the MIG process, remembering and applying a few basic guidelines makes a
difference when TIG welding aluminium. Again, choosing the correct TIG welding machine
is vital. You’ll need an AC/DC machine with sufficient power to weld the thicknesses of
aluminium you’re working with. Machines such as R-Tech’s AC/DC TIG161 and
170EXT exhibit the characteristics of a good TIG machine.
 So the first advice for TIG welding aluminium is to make sure you use a suitable machine.
 Again, as for MIG (or any welding process), make sure to clean your material thoroughly
before welding. If it’s dirty or oxidised, use a dedicated stainless-steel wire brush. And if it’s
oily, degrease it thoroughly.
 When TIG welding aluminium, torch set-up is critical. Make sure the torch has a suitable
duty cycle for the amperage you’re using. Generally, avoid using very lightweight, light-duty,
TIG torches on aluminium – you risk burning the torch out.
 As you start welding, be sure to allow the weld puddle to pool before you introduce the filler
rod. If you don’t, the rod is likely to stick to the workpiece.
 The quality and condition of torch consumables is also critical when TIG welding aluminium.
If in any doubt about optimum combinations of gas cup, tungsten type and electrode
diameter, seek advice from your TIG welding machine’s supplier. It all comes down to your
specific project and what you’re trying to achieve.
 For best results, match your TIG filler rod to the grade of aluminium that you’re working
with. Typical grades include 4043A (5% Si) and 5356 (5% Mg). Make sure to match the rod
thickness to the specific welding task too. And remember to wipe your filler rod clean to
remove any oily residue.
 Because aluminium is such a sensitive material, learn how to use a foot pedal when TIG
welding – or a TIG torch with a variable amperage control. Both aid precise, controlled TIG
welding of aluminium.
 Additionally, remember to set your AC frequency and balance to suit the aluminium you’re
working with. R-Tech’s Ben Steger says:
‘In my experience, the frequency sweet spot with aluminium is usually around 80–120 Hz.
And remember to set your AC balance to a suitable value for the work; start with 30–35% for
clean aluminium, then gradually increase the percentage on dirtier material so the arc lifts
the oxide off.’
Welding Cast Iron
When you combine carbon and iron, the result is the metal we call cast iron. It’s durable,
resistant to wear and has been in widespread use for centuries. Even with the development
and use of other – arguably more specialised and exotic – metals, this workhorse material
continues to be used widely. Here’s some advice on welding cast iron from the R-Tech
team…
Why is cast iron welding difficult?
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There are many different grades of cast iron and the weldability of these grades varies
considerably. So-called grey cast iron is the most common; it’s the material that we’re
dealing with in this article (the others are known as malleable cast iron and ductile cast iron).
Can you weld cast iron?
It’s difficult, but certainly not impossible. Despite its widespread use for so long, cast iron
continues to have a reputation for being a difficult material to weld. This is largely due to its
high carbon content (often 2.5–4%), and the hardening and brittleness caused by carbon
migration during the welding process.
Without detailed metallurgical analysis it can be hard – if not impossible – to tell different
grades of cast iron apart, let alone determine the brittleness of a particular metal. Yes,
although it’s wrong to say all cast iron is brittle, many grades are. This has contributed to cast
iron’s reputation for being highly sensitive and prone to cracking during welding.
MIG, TIG or MMA?
Depending on who you talk to and specific project details, you might be able to use MIG and
TIG to weld cast iron in some circumstances. However, this usually comes with strong
cautions. The general consensus among the R-Tech team is that manual metal arc welding
(MMA) should initially be the go-to process for welding cast iron.
This is particularly so with repairs to castings. These form the majority of cast iron welding
work (the brittleness of cast iron castings often leads to breakage). Typical projects? How
about mending a turbocharger housing or motorcycle exhaust flange, repairing a lathe’s
broken tail-stock, or fixing the leg of a cast iron stove?
MMA arc welding cast iron

Good practice and patience are essential. Here’s some useful advice for welding with cast
iron:
 Control the expansion and contraction of your cast iron workpiece(s). It’s very important to
pre-heat the cast iron gently to minimise thermal shock – particularly if you’re welding with
cast iron rods. Don’t pre-heat cast iron beyond 760°C (1400°F). This will take it out of its
austenitic phase, and into a critical temperature range where it will change further as it
approaches its melting point. Wherever possible, heat the whole casting and weld using the
lowest possible amperage to minimise local heating of the metal.
 As well as the point made above, it’s also helpful to keep the workpiece warm while welding
and to cool it as slowly as possible afterwards. You may even consider bedding the welded
casting in sand to help it cool slowly. Whatever you do, don’t use compressed air for cooling
or throw cold water on the workpiece (it’s happened!). Cast iron really doesn’t like being
cooled too quickly. If you hear ‘tinkling noises’ from the cooling work, it probably means
there’s been some internal fracturing. That’s not good.
 Keep your welding rod vertical.
 Stagger your welding as much as you can. For instance, you may be able to weld in another
area of the workpiece while your first weld cools. Welding a series of small segments like
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this, rather than attempting one long weld, helps prevent localised over-heating, build-up of
residual stresses and cracking. A good rule of thumb? Avoid single runs of welding that
exceed 10x the diameter of your welding rod.
 Clean your workpiece after every weld.
 For additional strength in a welded cast iron joint, consider drilling, tapping and studding the
joint before completing the weld.
 Wherever possible, seal existing cracks to avoid them being extended. Creating a V- or U-
groove around cracks and joints in cast iron helps ensure that the weld doesn’t just sit atop
the crack – and helps you achieve maximum penetration and weld integrity. Using a U-
groove with rounded edges may help avoid heat build-up which can aggravate carbon
migration.
 Take your time when welding cast iron. Patience is always helpful when welding, but the
particular challenges of cast iron make thorough preparation of your workpiece essential.
Thoroughly remove rust, oil grease and any other contaminants, take your time and get the
job right.
What kind of welding rod do you use on cast iron?
One of the attractions of using MMA for cast iron is the wide range of available stick welding
electrodes, including machinable and non-machinable variants. A Nickel (Ni) MMA welding
rod for cast iron (sometimes called ‘cold cast rod’) often helps. They’re not cheap, compared
with Ferro-Nickel rods, but they can make a big difference to your cast iron welding. Both
types of cast iron rod incorporate specialised high-Graphite flux to limit undesirable carbon
migration in and around the weld.
MIG welding cast iron

Although cast iron can be welded with the MIG process and specialised flux-cored electrode
wires, the resulting welded joint won’t be as strong as with MMA arc welding. As mentioned
earlier, the R-Tech team recommends MMA stick welding as first choice for welding cast
iron.
TIG welding cast iron

Opinions on the use of TIG welding for cast iron range from it being possible with
specialised filler rods, to its complete unsuitability due to an open arc process such as TIG
giving no opportunity for carbon migration. It’s not something the R-Tech team advocates.
Again, their recommendation is to use MMA stick welding for cast iron.
Can cast iron be welded or brazed?
Cast iron can definitely be welded, and it can also be brazed – including with TIG brazing.
Depending on the specific cast-iron welding project, R-Tech Welding Supplies’ Mike Gadsby
suggests considering this as a jointing option:
‘TIG brazing, with a TIG welding machine, may offer a satisfactory alternative to other
processes. With TIG brazing you use lower amperage to heat the workpiece, but without
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actually melting the cast iron. There’s no need to use flux, as you would do when brazing
with oxy-fuel. That’s because you can use the gas shroud effect of the TIG torch (use argon)
to shield the brazing zone. Run DC current at around 50% normal amperage and use
something like Phosphor Bronze No8 (C11) or Sifalbronze No.32 rods. As usual, cleanliness
is critical, so you must be very thorough with your preliminary deoxidising and degreasing.
With the understanding that you won’t achieve the strength and joint integrity that welding
can achieve, TIG brazing may be worth considering – remember to use a suitable filler rod,
lower temperatures and fill-in with braze.’
Welding Stainless Steel
There’s knowing how to weld steel and there’s knowing how to weld stainless steel. The
latter, renowned for its corrosion resistance and use where hygiene is essential, distorts easily
when heated. However, its lower thermal conductivity means heat energy isn’t dispersed
from the welding zone so fast, which helps during welding. Overall, it’s easy to work with,
but with the help of the following tips and advice, you should soon be on the way to stainless
mastery…
Can you weld stainless steel?
Yes, absolutely. And you can do it with the MIG welding process, TIG welding or MMA
(stick welding). Whether you’re a newcomer to welding or a seasoned professional, it’s
probable that welding stainless steel will eventually find its way into your welding skill set.
Is welding stainless steel difficult?
As with all weldable metals, stainless steel comes with its own peculiarities and behaviours
under the arc. Getting the best from this alloy (also called inox steel or inox), with its
minimum 10.5% Chromium content, can take a lifetime. Along with aluminium, it’s
undoubtedly one of the more challenging materials to weld.
However, whether you’re just starting out or work regularly with this material, a few tips will
serve as a valuable learning aid – or a helpful reminder…
Which welding is best for stainless steel?
In this article, we draw on the expertise of the R-Tech team to assemble a selection of tips
and advice relating to three common methods for welding stainless steel: MIG welding; TIG
welding; and manual metal arc welding (MMA). Which is best for welding stainless steel?
Choosing the best process really does come down to the specifics of the task – and the
qualities required from the finished weld. If cost is the key factor it could be MMA; but for
precision with thin materials, it’s probably going to be TIG. Let’s explore the three processes.
But first, here’s an important reminder about safety when welding stainless steel.
Is welding stainless steel harmful to your health?
The short answer is that stainless steel welding comes with potentially severe health risks –
not least from Cadmium and Chromium (Vi) fume. Suitable safety measures, including local
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exhaust ventilation (LEV) and welders’ personal protective equipment (PPE) such as air-fed
welding masks are therefore essential.
MIG welding stainless steel

Can you MIG weld stainless steel?
Again, yes you can. Firstly, as with any welding process, make sure your MIG welding
machine is set up correctly for welding stainless steel.
We recommend that you always fit a Teflon wire liner; this will ensure good wire feed as
well as preventing wire contamination. Stainless steel may be highly corrosion resistant, but
it’s also susceptible to contamination. When welding stainless steel with MIG, any ferrous
material (including contamination by a steel liner) in the weld pool can easily cause rust spots
on finished work.
 Naturally, you’ll also make sure your MIG torch is in good condition before starting to weld.
As with welding aluminium, it may also make sense to buy a torch sized larger than you’d
use for normal steel. Because, welding stainless steel produces more heat, the larger torch
will carry higher amperages better.
 Reverting to contamination, it’s vital to use only stainless steel wire brushes and
grinding/cutting discs whenever working with stainless steel.
 As well as the vulnerability of stainless steel to ferrous contamination, you need to ensure
that your working area is free from iron or steel dust, or any ferrous oxides. This may sound
trivial, but it’s vital. Cleanliness of materials and workspaces is always important for good
welding. With stainless steel, avoiding even the tiniest particulate contamination is critical.
 Next comes that old favourite: correct wire type and diameter. As ever this is project
specific, so seek advice.
 More advice shared with aluminium welding is the importance of clamping and tack welding
your workpiece to avoid movement and distortion through cracking. Mike Gadsby, one of R-
Tech Welding Equipment’s sales advisors (and an experienced welder) says:
‘Think about staggering your stainless steel welds to mitigate the risk of heat distortion
caused by the material’s thermal properties.’
What gas do you use for MIG welding stainless steel?
As ever, correct gas choice matters when MIG welding stainless steel. You may be using
pure argon or a blend of argon and minor gases to improve starting. Or maybe even a
specialist stainless gas mix (such as BOC’s Stainshield range of argon, helium and carbon
dioxide), especially for more-exotic stainless steels such as Inconel, Hastelloy or Monel
alloys. With stainless MIG welding, you’ll use a slightly higher gas-flow rate of around 14–
16 LPM. We recommend contacting gas suppliers to discuss gas requirements for your
specific project.
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TIG welding stainless steel

For TIG welding stainless steel, you can use a DC-only machine or AC/DC TIG welding
machines in DC-mode. Importantly, make sure your machine has sufficient power to weld
stainless steel. Whether you’re unsure about your existing machine’s capability, or buying a
machine for stainless steel welding, ask the machine’s supplier for help – including advice on
TIG welding stainless steel settings.
 Yet again, cleanliness is everything when you TIG weld stainless steel. Clean the workspace
and material thoroughly. As with MIG, if it’s dirty, use a stainless-steel wire brush that’s only
used for stainless steel. And if it’s oily, always degrease it thoroughly. Because of the risk of
ferrous contamination, you can’t be too clean or too careful.
 Get your TIG torch set-up for stainless. In particular, make sure the torch has the appropriate
duty cycle for the amperage being run. Never cut corners; if the torch isn’t up to the task,
invest in one that is.
 Don’t overlook all-important torch consumables either. Paying attention to having the
appropriate gas cup, selecting your tungsten type correctly, and getting the electrode
diameter just right are vital. Because stainless steel benefits from generous gas coverage,
use a slightly larger diameter gas cup than usual. Better still, fit a gas lens (such as the TIG
Zone eVo-FLO cover kit) to boost gas flow over the weld, keep it cool and provide extra
shielding for the weld pool.
 As ever, make sure to choose the correct rod for the grade of stainless steel that you’ll be
welding (widely-used grades include 316, 308 and 312 stainless). Correct rod thickness is
also essential: thinner stainless steel demands thinner rods to deliver required deposition
rates. Again, this is job-specific, so seek advice from your TIG filler rod supplier or rod
manufacturer. And while we’re discussing filler rods, make sure to wipe your filler rod clean
to remove any oily residue. It’s that cleanliness and contamination thing again… And of
course, when you weld, do wait for the weld puddle to pool before you introduce the rod.
 Just as for TIG welding aluminium, control is everything. For optimum control and precision,
use a TIG foot pedal or a TIG torch with variable amperage control.
 Consider pulse welding thinner stainless steel. Welding the face of a plate can be very
different to welding, say, the edge of the same piece. When TIG welding stainless steel,
pulse welding helps reduce distortion by minimising the heat going into the weld – while
simultaneously optimising penetration. If this is a consideration, make sure your TIG welding
machine has pulse welding capability. All R-Tech TIG machines do – covering the range 0.5–
50 Hz.
MMA welding stainless steel

We’ve looked at MIG and TIG welding. Now we’ll touch briefly on MMA arc welding of
stainless steel. It’s the simplest of the three processes to set up (most importantly, choose the
right electrode for the weld). It’s also the cheapest way to weld stainless alloys. Assuming
that you have a welding machine with stick welding capability, all you really need to start are
some suitable rods. There’s no gas, torch, foot pedals or torch consumables…It’s welding at
its simplest.
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 Stainless steel moves on welding tables, so make sure you clamp or tack weld it to your
workpiece.
 Choose the correct electrode for the workpiece (again, 316, 308 or 312 grade are typical).
 Remember that you won’t be able to weld thin sheets of stainless steel. Many welders
struggle with stainless sheet less than 2mm thick. It’s all down to the lower controllability of
MMA arc welding for such applications.
 Thin sheet may be a struggle. But in comparison, welding mild steel to stainless steels or
high-carbon tool steels really plays to MMA’s strengths.
 Pre-heating often helps with some stainless steels. That’s because it can help prevent
cracking. Pre-heating is typically done with a blow torch, or with an oxy acetylene or oxy
propane torch.
MMA Arc Welding - How to Arc Weld

 What is MMA ARC Force?
Arc Force can be found on our range of AC/DC Tig Welders both Digital and
Analogue versions, it is also available on our Digital DC Tig Welders
This controls the arc during welding and will automatically adjust the
voltage/amperage to maintain a stable arc, so it will maintain a good weld bead if if
arc length changes during weld.
If the rod is pushed very close into the weld (tight arc length) the machine will
compensate for the drop in welding volage by increasing it momentarily.
Lower setting is a more soft smooth arc, higher setting is a more aggressive arc (some
call a more digging arc)
If you like ARC MMA welding with a tight arc (the stick is very close to workpiece)
this will help stop the rod from sticking to the material.
As with many advanced settings this can be used in different ways.
1. If you have a low setting of 30% - 50% for welding the you can keep a normal arc
length and use the normal amperage for the job to hand.
2. If you like to keep a very tight arc, you can increase the arc force above 50% + and
then reduce the main amperage, this will allow a tight arc length and prevent arc
blow.
It is best to get some scrap metal and change the settings and wirte them down and
compare each weld when finished, once you get it welding just ask you like it record
these settings.
Page 36 of 38
 What is Anti-stick technology on your MMA ARC Welders?
Anti-Stick technology is found on our range of ARC welders and is automatic in its
operation (no setting is needed on front panel)
When the rod gets stuck to the workpiece (short circuit) the welding power is turned
of automatically by the arc welder to stop the welding machine getting overloaded
and allows easy removal of the arc electrode from workpiece.
 What is Hot Start on your ARC MMA Welders
Hot-Start is used to give better arc starting.
When the arc is started (electrode touched to workpiece) the voltage / amperage is
boosted, once the arc has started and stable the arc welder will then continue with the
normal welding voltage for amperage selected.
This is found on our MMA arc welders below
R-Tech PROARC 135 & 175 MMA ARC Welders
 What is V.R.D on our Digital TIG Welders?
V.R.D "Voltage Reduction Device" is a safety system found on our Digital range of
TIG welders which have MMA ARC Welding Function.
Normal O.C.V (Open circuit voltage) is between 70-95 volts DC, when the machine is
put in MMA mode it is constantly LIVE so if you touch the stick electrode onto
workpiece it would stike an arc immediately.
When V.R.D is turned on the OCV is lowered to 20V (+/- 3v) so is much safer,
especially when long welding cable are used.
Once the arc electrode has touched the workpiece the weld arc starts and welding
carries on as normal.
When welding in V.R.D mode you may experience a slight delay in arc starting, the is
normal.
It can be slightly harder to strike an arc on very rusty / dirty materials so you may
have to scratch harder or clean the metal before welding.
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 On your MMA stick welders you list a Scratch Start Tig Torch Kit, how
does this work?
Arc Welders can be converted for tig welding by fitting a tig torch that plugs into
where electrode holder fitted, the torch has a gas hose coming off it that you fit to a
gas bottle with regulator valve . On the tig torch you have a valve that you open and
this allows gas to flow, you then scratch the tungsten onto work to initiate arc and you
are then tig welding, once finished you pull torch away from work to stop arc and
then turn gas valve off.
Its a very basic tig system and suits those who only wish to tig weld rarely.
An actual tig welder has benefits of HF start that start arc when you press torch button
so you don't have to scratch start that wears down tungsten, and when you want to
stop welding you just release trigger and arc stops & turns off the gas, on the system
above you just pull away as MMA welder is 'live' all the time this can leave poor weld
at end of weld.
As the price for a HF DC Tig welder is much lower nowadays we would advise to
purchase a dedicated DC Tig Welder with HF start and auto gas on / off as once you
have purchased the ARC inverter powersource, torch and regualtor etc there is not
much difference in the end price.
Page 38 of 38

ACUWELD MIG &TIG Welding Wires

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ACUWELD MIG &TIG Welding Wires

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ACUWELD Welding Consumables – MIG & TIG WIRES

ACUWELD TIG WIRE- MODEL/VARIANT- E308L, 309L, 316L, 202

Key Product features

Weld Metal Analysis in %

Tensile Strength (N/mm2)—500-620

Yield Strength (N/mm2)—400-510

Weld Metal Analysis in %

C Min Si S P Cu,Including Cu in Coating

As Welded GMAW 100% CO2

Tensile Strength- 500-640 MPa

Elongation in 2”- 24% Min.

Submerged Arc Welding Wire designed to be paired to meet any industry

Submerged Arc Welding Wire Analysis in %

STANDARD SIZES : Wire Diameter

mm 1.6 2.0 2.4 3.2 4.0 4.8

Chemical Composition of Copper Coated Welding Wire

C % Cr % Ni % Mo % Mn % Si% P% S% V% Cu% Ti Zr Al

AWS ER- 0.06- 0.15 1.40- 0.80- 0.03

AWS ER- 0.15 0.90- 0.40- 0.03 0.05- 0.02- 0.05-

AWS ER- 0.06- 0.15 0.90- 0.45- 0.03

MIG Welding guide

WHAT IS MIG WELDING?

Here are some advantages to MIG welding:

 The ability to join a wide range of metals and thicknesses

MIG welding Advantages and

The advantages of MIG welding

MIG weld quality

Fewer stops and starts

Electrode stub loss? What’s that?

MIG works with many metals or alloys

MIG welding is clean

Disadvantages of MIG welding

MIG welding costs more (to set up)

The wind problem

What are MIG wires used for?

What MIG is better for?

Throw in MIG welding’s renowned cleanliness, long-pass capability, applicability to metals

Where MIG isn’t so good?

MIG welding disadvantages

 MIG welding set up costs

What is better TIG or MIG welding?

Advantages of MIG over TIG

 All things being equal, MIG is easier to learn.

Is gasless MIG welding any good?

How MIG welding works

Avoiding common MIG welding defects

MIG welding is versatile

Advantages of MIG welding

Disadvantages of MIG welding:

1. WHAT IS TIG WELDING?

A number of tungsten alloys are also available (including Thoriated Tungsten)

 Holds a point longer and starts well at low amperages.

TIG WELDING BASICS

How TIG welding works

A non-consumable tungsten electrode

Inert shielding gas

The versatility of TIG welding

Ensuring quality TIG welds

Pros and cons of TIG welding

Advantages of TIG welding

Disadvantages of TIG welding

What’s the Difference Between MIG and

Is MIG or TIG welding better?