MIG/MAG Welding Consumables MIG/MAG Welding Consumables

Wire designation acc AWS A-5.18: How to check the quality of welding wires:
Chemical composition of the solid Cast diameter
wire or of the weld metal in case Helix size - limited to 25mm
of composite electrodes to avoid problems with arc
Minimum UTS of weld metal (ksi)
wandering!

Standard number

Cast diameter improves the contact force and defines the contact
AWS A-5.18 ER 70 S-6 point; usually 400-1200mm.
Designate an electrode/rod (ER)
or only an electrode (E)

Solid (S) or composite (C) wire

Contact point close to Contact point remote from
contact tip end - GOOD! contact tip end - POOR!

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MIG/MAG Shielding Gases MIG/MAG Shielding Gases

Gas shielded Ar Ar-He He CO2

metal arc welding

MIG process (131) MAG process (135) Argon (Ar):

Higher density than air; low thermal conductivity - the arc
has a high energy inner cone; good wetting at the toes;
BS EN 14175 low ionisation potential.
Helium (He):
Lower density than air; high thermal conductivity -
uniformly distributed arc energy; parabolic profile; high
Group I - Ar, He Group R - Group M - Ar + Group C - ionisation potential.
and Ar-He Ar + H2 CO2/O2 CO2, CO2 + Carbon Dioxide (CO2):
mixtures (<35%) (<50/15%) O2 (<30%) Cheap; deep penetration profile; cannot support spray
transfer; poor wetting; high spatter.

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MIG/MAG Shielding Gases MIG/MAG Shielding Gases

Gases for dip transfer: Gases for spray transfer

 CO2: Carbon steels only; deep penetration; fast
welding speed; high spatter levels.
 Ar + up to 25% CO2: Carbon and low alloy
steels; minimum spatter; good wetting and bead
contour.
 90% He + 7,5% Ar + 2,5% CO2: Stainless
steels; minimises undercut; small HAZ.
 Ar: Al, Mg, Cu, Ni and their alloys on thin
sections.
 Ar + He mixtures: Al, Mg, Cu, Ni and their alloys
on thicker sections (over 3mm).
 Ar + (5-18)% CO2: Carbon steels; minimum
spatter; good wetting and bead contour.
 Ar + 2% O2: Low alloy steels; minimise undercut;
provides good toughness.
 Ar + 2% O2 or CO2: Stainless steels; improved
arc stability; provides good fusion.
 Ar: Al, Mg, Cu, Ni, Ti and their alloys.
 Ar + He mixtures: Al, Cu, Ni and their alloys;
hotter arc than pure Ar to offset heat dissipation.
 Ar + (25-30)% N2: Cu alloys; greater heat input.

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