MIG Welding

Manufacturing and Materials

Processes
 (GMAW) MIG Welding
 Gas Metal Arc Welding (GMAW) is
frequently referred to as MIG welding. 
 MIG welding is a commonly used high
deposition rate welding process. 
 Wire is continuously fed from a spool. 
 MIG welding is therefore referred to as a
semiautomatic welding process. 
 MIG Welding Benefits
  All position capability
  Higher deposition rates than SMAW
  Less operator skill required
  Long welds can be made without
starts and stops
  Minimal post weld cleaning is
required
 MIG Welding Shielding
Gas
 The shielding gas, forms the arc
plasma, stabilizes the arc on the
metal being welded, shields the arc
and molten weld pool, and allows
smooth transfer of metal from the
weld wire to the molten weld pool. 
 The primary shielding
gasses used are:
 Argon
  Argon – 95% to 5% Oxygen
  Argon – 75% to 25% CO2
  Argon/Helium
 CO2 is also used in its pure form in
some MIG welding processes.  However,
in some applications the presence of
CO2 in the shielding gas may adversely
affect the mechanical properties of the
weld. 
 Welding Parameters and
Techniques
 Welding current
 Wire electrode extension
 Welding voltage
 Arc travel speed
 WELDING CURRENT
 The welding current is the electrical
amperage in the power system as the
weld is being made.
 welding current is directly related to wire-
feed speed (if the wire extension beyond
the guide tip is constant). As the wire-feed
speed is varied, the welding current will
vary in the same direction. In other
words, an increase (or decrease) in the
wire-feed speed will cause an increase (or
decrease) of the current.
 WIRE ELECTRODE
EXTENSION
 Wire extension or ”stick-out” is the
distance between the last point of
electrical contact, usually the end of
the contact tip, and the end of the
wire electrode.
 WIRE ELECTRODE
EXTENSION
 Controlling tip-to-work distance is
important. Long extensions result in
excess weld metal being deposited
with low arc heat. This can cause
poor bead shape and low
penetration. In addition, as the tip-
to-work distance increases, the arc
becomes less stable.
 WELDING VOLTAGE
 voltage setting directly controls the
arc length.
 In addition, a certain range is
required to maintain arc stability at
any given welding current level.
 ARC TRAVEL SPEED
 As the material thickness increases,
the travel speed must be lowered.
 For a given material thickness and
joint design, as the welding current is
increased, so is the arc travel speed.
The converse is also true.
 Higher welding speeds are attainable
by using the forehand welding
technique.
WELDING TECHNIQUES
 Torch Position
 Split the angle (90 degrees = 45 degree
split)
 5 degree rake
Good Voltage to Voltage to Too Fast Too Slow
Weld High Low
Less Stick
Out