GMAW / Mig Welding

Basic equipment setup and welding

procedures
Gas Metal Arc Welding

Is a process where a continuously fed

metal electrode ( Wire ) contacts the base
metal and produces heat . The arc is
shielded by an inert gas
GMAW Components
DC or Direct Current power supply
Electrode or wire feed controller
Wire drive roller assembly
Shielding gas source (cylinder) & regulator
Manually held Gun & ground clamps
Wire reel
GMAW component diagram
Gas Metal Arc Welding Principles
Gas metal arc welding is generally used
due to the high efficiency of filler metal
that can be deposited per hour.

GMAW is approximately 92% - 98% efficient

GMAW requires a shielding gas

Gas Metal Arc Welding Principles
The GMAW process is performed using
DCEP ( Direct Current Electrode Positive)

Alternating current is never used for

GMAW

DCEN is used only for a specialized

process using emissive electrodes
GMAW Advantages
Welding can be done in all positions
No slag removal required
High efficiency
Less work piece distortion
Large gaps bridged easily , Good for poor
fitup
High Weld Quality
Typical Setup for voltage
The GMAW machine is a Constant Voltage power
supply. This is set using the voltage dial

This setting can be monitored by the Volt meter

on the front panel of the welder

Ideal voltage settings can be found in the wire

manufactures data book
Typical Setup for Wire speed
The wire feed rate or speed is set using the dial on the
wire controller This setting increases or decreases
current or Heat. This setting is measured in AMPS or
IPM (inches per minute )

Ideal settings can be monitored by the Amp meter on the

front panel of the welder. Note : Some machines display
Current (Same as AMPS) or IMP

Ideal settings can be found in the wire manufactures data

book for both IPM and Current
Shielding Gas
Air in the welding zone is displaced by inert gas to
Shield the molten weld pool and prevent it from
contamination from Oxygen, Nitrogen and Water
present in the atmosphere.
Insufficient gas flow will not displace the
atmosphere resulting in porosity or voids in the
deposited weld.
Flow is measured in CFH (Cubic Feet per Hour).
Insufficient Shielding Gas coverage

Gas not turned on

Flow rate not properly adjusted
Leaks in the hose supplying the shielding
gas to the machine
GMAW / MIG Gun loose at wire drive
connection
Spatter buildup on gas cup
Windy environment
Excessive Gas coverage
Will cause porosity.
The turbulence caused by the rapid flow of
shielding gas exiting from the gas cup will
draw the surrounding atmosphere into the
stream of gas.
It will reduce weld pool temperatures
causing decreased penetration .
Check the Manufactures data for
settings