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Basic Mig Welding Process
Basic Mig Welding Process
In Gas Metal Arc Welding (GMAW), also known as Metal Inert Gas (MIG) welding, an electric
arc is established between the workpiece and a consumable bare wire electrode. The arc
continuously melts the wire as it is fed to the weld puddle. The weld metal is shielded from the
atmosphere by a flow of an inert gas, or gas mixture. Figure 1-1 shows this process and a
portion of the welding torch. The mig welding process operates on D.C. (direct current) usually
with the wire electrode positive. This is known as ”reverse” polarity. ”Straight” polarity, is seldom
used because of poor transfer of molten metal from the wire electrode to the workpiece. Welding
currents of from 50 amperes up to more than 600 amperes are commonly used at welding
voltages of 15V to 32V. A stable, self correcting arc is obtained by using the constant potential
(voltage) power system and a constant wire feed speed. Continuing developments have made
the mig process applicable to the welding of all commercially important metals such as steel,
aluminum, stainless steel, copper and several others. Materials above .030 in. (.76 mm) thick
can be welded in all positions, including flat, vertical and overhead. It is simple to choose the
equipment, wire electrode, shielding gas, and welding conditions capable of producing high-
quality welds at a low cost. Basic Mig Welding Process
ADVANTAGES
The mig welding process provides many advantages in manual and automatic metal
joining for both low and high production applications. Its combined advantages when
compared to covered (stick) electrode, submerged arc, and tig are:
1) Welding can be done in all positions.
2) No slag removal required.
3) High weld metal deposition rate.
4) Overall times for weld completion about 1/2 that of covered electrode.
5) High welding speeds. Less distortion of the workpiece.
6) High weld quality.
7) Large gaps filled or bridged easily, making certain kinds of repair welding more
efficient.
8) No stub loss as with covered electrode.
Process Variations-Metal Transfer
The basic mig process includes three distinctive process techniques: short circuiting metal
transfer, globular transfer, and spray arc. These techniques describe the manner in which metal
is transferred from the wire to the weld pool. In short circuiting metal transfer, also known as
”Short Arc”, ”Dip Transfer”, and ”Microwire”, metal transfer occurs when an electrical short circuit
is established. This occurs as the molten metal at the end of the wire touches the molten weld
pool. In spray arc welding, small molten drops of metal are detached from the tip of the wire and
projected by electromagnetic forces towards the weld pool. Globular transfer occurs when the
drops of metal are quite large and move toward the weld pool under the influence of gravity.
Factors that determine the manner of metal transfer are the welding current, wire size, arc
length (voltage), power supply characteristics, and shielding gas.
Figure 1-1 – Types of Metal Transfer
The flux-cored electrode is a continuous, tubular electrode wire, with a sheath of low
carbon, mild steel and core containing deoxidizers, slag formers and arc stabilizers in
powder form. Both strip and core materials are carefully monitored to conform with
rigorous specifications. Automatic controls during production pro- vide a uniform, high
quality product. Flux-cored wires are specifically designed to weld mild steel using either
CO gas or Argon-Co gas mixtures. Flux-cored arc welding offers many inherent
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advantages over stick electrode welding. Higher deposition rates (typically double) and
increased duty cycles (no electrode changing) mean savings in labor costs. The deeper
penetration achieved with cored wire also permits less joint preparation, yet provides
quality welds free from lack of fusion and slag entrapment. Also flux-cored wire welding
is easy to learn.