University of kirkuk

College of engineering
Mechanical dept. – third stage

MIG Welding

Supervised by: Mr. Bilal Qasim

Prepared by: Mohamed jabbar ezzulddin
Definition:
Metal Inert Gas (MIG) welding is a gas metal arc welding
(GMAW) process that uses a continuous solid wire electrode which is heated and
fed into the weld pool from a welding gun. The two base materials are melted
together which causes them to join. The welding gun also feeds an inert shielding
gas alongside the wire electrode, which helps protect the process from airborne
contaminants.

Introduction:
Metal inert gas welding, or MIG welding, is the most widely used of the arc
welding processes. It is suitable for everything from hobbies and small fabrications
or repairs, through to large structures, shipbuilding and robotic welding. MIG can be
used on a broad range of materials and thicknesses, and the latest "SuperPulse"
technology enables MIG to give a finish that is similar to that obtained with TIG
(tungsten inert gas) welding, yet with the speed for which MIG is renowned. The
concept underlying MIG welding is simple, with the arc being struck between the tip
of the reel-fed wire as it emerges from the torch, and the work-piece. A shielding
gas prevents oxidation forming, or the use of some flux cored wires avoids the need
for a shielding gas. With most MIG welding sets, the user sets the wire feed speed,
which determines the current; then the user sets the voltage to suit that current. Ease
of use is clearly a major benefit of MIG in many applications, but speed is also
important. It is far quicker to lay down weld metal with MIG than TIG, MMA
(manual metal arc - or 'stick' welding) or gas welding.
Steps of work:

1. Safety first:
Before tackling any welding project, you need to make sure you have the
proper safety apparel and that any potential fire hazards are removed from the
welding area.
2. Metal preparation:
Unlike stick and flux-cored electrodes, which have higher amounts of special
additives, the solid MIG wire does not combat rust, dirt, oil or other
contaminants very well.
3. Equipment preparation:
Checking equipment is an important step like, checking the cables and
connections, selecting the electrode polarity and setting the gas flow.
 4. Wire selection:
For steel, there are two common wire types. Use an AWS classification
ER70S-3 for all-purpose welding. Use ER70S-6 wire when more deoxidizers are
needed for welding on dirty or rusty steel. As for wire diameter, .030-inch diameter
makes a good all-around choice for welding a wide range of metal thicknesses in
home and motorsports applications.

5. Gas selection:

A 75 percent argon/25 percent carbon dioxide blend (also called 75/25 or

C25) works as the best all purpose shielding gas for carbon steel. It produces the
least amount of spatter, best bead appearance and won't promote burn-through on
thinner metals. 100% CO2 provides deeper penetration, but also increases spatter
and the bead will be rougher than with 75/25.

6. Wire stick-out:

Stick-out is the length of un-melted electrode extending from the tip of the
contact tube and it does not include arc length. Generally, maintain a stick-out of
3/8 inch and listen for a sizzling bacon sound. If the arc sounds irregular, one
culprit could be that your stick-out is too long, which is an extremely common
error.

7. Travel angle:

Travel angle is defined as the angle relative to the gun in a perpendicular

position. Normal welding conditions in all positions call for a travel angle of 5 to 15
degrees. Travel angles beyond 20 to 25 degrees can lead to more spatter, less
penetration and general arc instability.
Advantages of MIG welding:

1- Higher welding speeds

2- Higher quality welds can be produced much faster
3- Less post welding cleaning
4- Low skill factor required to operate
5- More versatile and can be used with a wide variety of metals and alloys
6- No fluxes required in most cases

Disadvantages of MIG welding:

1- Higher initial setup cost

2- Atmosphere surrounding the welding process has to be stable
3- Higher maintenance costs due to extra electronic components
4- The setting of plant variables requires a high skill level
5- Less efficient where high duty cycle requirements are necessary
6- Radiation effects are more severe

References:

https://www.millerwelds.com/

https://en.wikipedia.org/