MESIN KIMPALAN MIG

MIG (Metal Innert Gas Welding) ataupun dikenali sebagai Kimpalan logam Gas Lengai, dalam proses
ini elektrod akan melebur dan bercampur dengan leburan logam induk untuk membentuk kopak
kimpal. Oleh yang demikian, eletrod mestilah dibekalkan arus yang berterusan sepanjang proses
kimpalan itu dijalankan. Untuk bekalan elektrod yang berterusan, elektrod diperbuat dalam bentuk
dawai yang boleh dihulurkan keluar dari muncung pengimpal secara automatik pada kelajuan yang
ditentukan. Gas pelindung dibekalkan melaui muncung kimpal seperti yang dilakukan dalam
kimpalan TIG, proses ini boleh dilakukan secara automatik atau separauh automatik. walau
bagaimanapun, alat kelengkapan MIG adalah lebih rumit kerana prosesnya memerlukan huluran
slektrod yang berterusan dan seragam.

MIG digunakan dengan meluas untuk kimpalan yang memerlukan kadar pengeluaran tinggi,
contohnya dalam kilang pembuatan.

KOMPONEN MIG
  Bekalan kuasa

Pada kebiasaannya, mesin untuk kimpalan MIG ialah penjana motor atau penerus jenis bekalan
kuasa bervoltan malar yang membekalkan arus terus sehingga 25 ampere. Secara automatiknya
voltan akan berubah-ubah mengikut jarak celahan diantara hujung dawai elektrod dengan kerja,
manakala arus pula berubah secara songsang ketika kerja dilakukan.

 Penembak kimpalan

Penembak bekalan biasanya digunakan untuk mengeluarkan dawai elektrod dan gas pelindung.
Kaedah mengeluarkan dawai elektrod dari muncung penembak ialah secara tarik atau tolak.

 Gas pelindung

Untuk MIG, gas karbon dioksida digunakan. Gas karbon digunakan untuk mengimpal MIG keluli
karbon.

 Dawai elektrod

Sangat penting dan mestilah dari logam yang mempunyai kerencaman yang sama dengan bahan
kerja yang dikimpal.
Kelebihan kimpalan MIG :

 Proses boleh di automasikan (digabungkan dengan robot)

 Proses lebih cepat

 Hasil kimpalan bermutu tinggi

 Arka dan kubang kimpal mudah dilihat semasa melakukan pengimpalan

 Kimpalan bolah dibuat pada semua kedudukan

 Boleh mengimpal semua jenis logam utama

MIG WELDING: SETTING THE CORRECT PARAMETERS

Basic tips to get you started with MIG welding, including information on new equipment and
settings.

Optimal performance with your MIG welder

Unless you weld for a living, it is often difficult to know if your MIG welder is set up for optimal
performance. If you find yourself asking questions such as "am I using the proper voltage?” or “do I
have too much or too little wire?” then this article is for you! We will touch on the basics of properly
setting up your welder, and then look at what your weld bead is telling you.

Equipment

Good equipment makes MIG welding easier, while poor equipment can cost you dearly in frustration
and weld quality. MIG welders such as the Millermatic® 211 and Millermatic 141 are ideal for the
occasional welder. If you’re looking for a machine with multiple welding capabilities, we recommend
multiprocess welders like the Multimatic® 215 and Multimatic 220 AC/DC.

Some welding machines include technology advancements, such as Auto-Set™ technology, which
sets optimal parameters automatically based on material thickness and wire diameter. This allows
you to focus on proper technique.

To determine which welding machine best fits your needs, watch Which Welder is Right for Your
Home or Shop or download this guide.

Getting the most from your machine

Regardless of your machine choice, read your owner's manual. It contains important information
about proper operation and safety guidelines. Most companies offer their manuals online.

The following basic guidelines are for MIG welding steel with solid wire. Joint design, position and
other factors affect results and settings. When good results are achieved, record the parameters.

1. Material thickness determines amperage. As a guideline, each .001 inch of material thickness
requires 1 amp of output: .125 inch = 125 amps.

2. Select proper wire size according to amperage. Since you don't want to change wire, select one
for your most commonly used thicknesses.
  30-130 amps: .023 inch

 40-145 amps: .030 inch

 50-180 amps: .035 inch

 75-250 amps: .045 inch

3. Set the voltage. Voltage determines height and width of the bead. If no chart, manual or
specifications are available for setting the correct voltage, you can try this: While one person welds
on scrap metal, an assistant turns down the voltage until the arc starts stubbing into the workpiece.
Then, start welding again and have an assistant increase the voltage until the arc becomes unstable
and sloppy. A voltage midway between these two points provides a good starting point.

There is a relationship between arc voltage and arc length. A short arc decreases voltage and yields a
narrow, ropey bead. A longer arc (more voltage) produces a flatter, wider bead. Too much arc length
produces a very flat bead and the possibility of undercut.

4. Set the wire feed speed. Wire speed controls amperage as well as the amount of weld
penetration. A speed that's too high can lead to burn-through. If a manual or weld specification
sheet is not available, use the multipliers in the following chart to find a good starting point for wire
feed speed. For example, for .030-inch wire, multiply by 2 inches per amp to find the wire feed
speed in inches per minute (ipm).

For wire size Multiply by Ex. using 1/8 inch (125 amps)

.023 inch 3.5 inches per amp 3.5 x 125 = 437.5 ipm

.030 inch 2 inches per amp 2 x 125 = 250 ipm

.035 inch 1.6 inches per amp 1.6 x 125 = 200 ipm

.045 inch 1 inch per amp 1 x 125 = 125 ipm

Examining the beads

One way to check your parameters is by examining the weld bead. Its appearance indicates what
needs to be adjusted.

Good weld: Notice the good penetration into the base material, flat bead profile, appropriate bead
width, and good tie-in at the toes of the weld (the edges where the weld metal meets the base
metal).
Voltage too high: Too much voltage is marked by poor arc control, inconsistent penetration and a
turbulent weld pool that fails to consistently penetrate the base material.

Voltage too low: Too little voltage results in poor arc starts, control and penetration. It also causes
excessive spatter, a convex bead profile and poor tie-in at the toes of the weld.

Travel speed too fast: A narrow, convex bead with inadequate tie-in at the toes of the weld,
insufficient penetration and an inconsistent weld bead are caused by traveling too fast.

Travel speed too slow: Traveling too slow introduces too much heat into the weld, resulting in an
excessively wide weld bead and poor penetration. On thinner material it may also cause burn-
through.

Wire feed speed/amperage too high: Setting the wire feed speed or amperage too high (depending
on what type of machine you're using) can cause poor arc starts, and lead to an excessively wide
weld bead, burn-through, excessive spatter and poor penetration.
Wire feed speed/amperage too low: A narrow, oftentimes convex bead with poor tie-in at the toes
of the weld marks insufficient amperage.

No shielding gas: A lack of or inadequate shielding gas is easily identified by the porosity and
pinholes in the face and interior of the weld.