Welding

Welding Methods MIG welding Procedures

Safety
Exercises

Welding Methods
There are many types of welding methods, for example these are :
TIG Welding MIG Welding Flux Cored Welding Stick Welding Submerged Arc Welding Resistance Welding Electron Beam Welding Robotic Welding Oxy-Acetylene Welding Brazing and Soldering

From the above, the highlighted methods are the main 4 different types of welding methods commonly used in building construction. We will be studying and working with MIG welding for class exercises and project work. There are also facilities to do Spot Resistance welding. The 4 main types of welding are described in the following:

Welding methods
Description
TIG Welding Gas Tungsten Arc Welding (GTAW) is frequently referred to as TIG welding. TIG welding is a commonly used high quality welding process. TIG welding has become a popular choice of welding processes when high quality, precision welding is required. In TIG welding an arc is formed between a nonconsumable tungsten electrode and the metal being welded. Gas is fed through the torch to shield the electrode and molten weld pool. If filler wire is used, it is added to the weld pool separately.

TIG Welding Benefits Superior quality welds Welds can be made with or without filler metal Precise control of welding variables (heat) Free of spatter Low distortion

Welding methods
Description
Stick Welding Shielded Metal Arc Welding (SMAW) is frequently referred to as stick or covered electrode welding. Stick welding is among the most widely used welding processes. The flux covering the electrode melts during welding. This forms the gas and slag to shield the arc and molten weld pool. The slag must be chipped off the weld bead after welding. The flux also provides a method of adding scavengers, deoxidizers, and alloying elements to the weld metal.

Stick Welding Benefits Equipment used is simple, inexpensive, and portable Electrode provides and regulates its own flux Lower sensitivity to wind and drafts than gas shielded welding processes All position capability

Welding methods
Description
MIG Welding Gas Metal Arc Welding (GMAW) is frequently referred to as MIG welding. MIG welding is a commonly used high deposition rate welding process. Wire is continuously fed from a spool. MIG welding is therefore referred to as a semiautomatic welding process.

MIG Welding Benefits All position capability Higher deposition rates than SMAW Less operator skill required Long welds can be made without starts and stops Minimal post weld cleaning is required

Welding methods
Description
Resistance Welding Resistance Spot Welding (RSW), Resistance Seam Welding (RSEW), and Projection Welding (PW) commonly use resistance welding processes. Resistance welding uses the application of electric current and mechanical pressure to create a weld between two pieces of metal. Weld electrodes conduct the electric current to the two pieces of metal as they are forged together. The welding cycle must first develop sufficient heat to raise a small volume of metal to the molten state. This metal then cools while under pressure until it has adequate strength to hold the parts together. The current density and pressure must be sufficient to produce a weld nugget, but not so high as to expel molten metal from the weld zone. Resistance Welding Benefits High speed welding Easily automated Suitable for high rate production Economical

MIG welding
Description Applications Procedures

Safety
Exercises

MIG Welding Shielding Gas The shielding gas, forms the arc plasma, stabilizes the arc on the metal being welded, shields the arc and molten weld pool, and allows smooth transfer of metal from the weld wire to the molten weld pool. There are three primary metal transfer modes: Spray transfer Globular transfer Short circuiting transfer The primary shielding gasses used are: Argon Argon - 1 to 5% Oxygen Argon - 3 to 25% CO2 Argon/Helium CO2 is also used in its pure form in some MIG welding processes. However, in some applications the presence of CO2 in the shielding gas may adversely affect the mechanical properties of the weld.

MIG or Metal Inert Gas welding

An electrical arc is created between a continuous, consumable wire electrode and the work piece The consumable wire functions as the electrode in the weld circuit and, also, as the source of filler metal

An inert shielding gas is used

To protect the electrode and weld pool from contamination To enhance the welding capabilities of the electrical arc Originally Argon or Helium Today reactive elements such as oxygen and carbon dioxide are usually mixed with the inert gas to improve welding performance

Close switch

Open switch

The MIG process

Can weld most commercial metals and alloys including: Steel Aluminum Stainless steel Produces little or no slag The arc and weld pool are clearly visible during welding Post weld cleanup is minimized

The travel speed and deposition rates in MIG welding

May be much higher than either TIG or Stick welding Result in greater speed and efficiency

By continuously feeding the wire

Electrode changing is minimized Weld defects caused by interruptions in the welding process are reduced

Continuously fed wire

Allows the operator to concentrate on arc control Makes MIG a simpler process to learn

MIG Welding
Can be done in most positions An asset for manufacturing and repair work where vertical or overhead welding may be required

A basic MIG welding system requires:

A power source B wire feeding mechanism C shielding gas cylinder D regulator / flow meter E MIG gun F a work clamp (grounded)

C A

B E

D C

F
E

The MIG welding power source converts

Primary power from an outside electrical source to secondary or usable power at the proper current and voltage to maintain a welding arc

Most MIG welding uses

Direct current, constant voltage power A reverse polarity weld circuit, so The electrode is positive Electricity flows from the negative work piece to the positive electrode in the MIG gun

The cylinder
Contains gas stored under pressure Should be handled very carefully During welding, inert shielding gas is dispensed from the cylinder Enhancing arc performance Shielding the weld area from contaminants

Connecting the work clamp to the work piece

Completes the weld circuit Enables current to flow

The regulator
Controls the flow of gas The amount of gas needed will vary

The wire feeders drive motor turns drive rollers that

Grasp the wire Pull it from a spool or reel Feed it at a controlled speed through a guide in the gun A separate control Allows the operator to adjust the tension on the wire Many types of wire feeders Used for different MIG welding applications Some are incorporated into MIG welding power sources Others are separate units

The MIG gun The trigger on the MIG gun activates

The wire feeding system Gas delivery Weld power

A nozzle in the gun

Directs shielding gas around the arc and weld pool

The contact tip at the front of the MIG gun

Transfers electrical current to the electrode wire

The cable liner

Encloses the electrode wire Must be compatible with the wire composition For flux cored or hard wire A stanless steel or mild steel liner is used For aluminum electrode wire The liner may be Teflon or a separate external feeder spool is used Liners Must match the electrode wire size to prevent poor feeding Some work with more than one size wire Eventually wear out from the continuous friction of the wire or from poor care A worn liner Will cause poor wire feeding and weld results

The Voltage Adjustment Control

Sets the weld power output voltage Once set, the voltage remains constant MIG power sources are constant voltage machines

To get the proper weld output for a particular MIG application

Voltage must be set on the power source Amperage must be set by adjusting wire feed speed

Amperage is determined by
Wire feed speed Measured in inches per minute, or IPM (or MPM, meters per minute)

The Wire Feed Speed Control

Adjusts wire feed speed Controls the amperage in the weld circuit The wire feeder may be separate from the power source

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Exercise 1 Name the items:

Exercise 1 Select 3 characteristics of the electrode wire:

Select 2 characteristics of the electrode wire:

Exercise 1 Identify 6 advantages of MIG welding:

Exercise 2 Identify components:

Exercise 2 Select 3 functions of the power source:

Exercise 2 Select 3 functions of the shielding gas cylinder

Exercise 2 Select 5 functions of the MIG gun/components

Exercise 2 Select 3 functions of the Wire Feeder

Exercise 2 Select 2 functions of the wire speed control Determines the Amperage Sets Welding Voltage Determines the Inches per Minute Setting

Select 2 functions of the voltage control Sets Welding Amperage Sets Welding Output as Required by the Application Sets the Weld Output Voltage

To add: (see instruction manual) -Safety issues - Overheating guide - Table of Voltage vs Wire Speed - Welding positions - Trouble shooting & welding practice etc