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I ntroduction to practical

application of wire feed welding


MIG Metal Inert Gas Welding
May be called GMAW (Gas Metal Arc Welding)
Avoid cutting in drafty or windy conditions
Molten pool is shielded by the inert gas envelope
Joints are stronger, more ductile, and more
corrosion resistant
Flux center wire has slag; Solid wire has no slag,
thus eliminating slag inclusion
Welded metal does not readily distort
Power Supply
Gas Supply
Wire feeder
Gun and Whip
Process
MIG Machine Operation
Wire is fed at a pre-set rate
Gas flows at about 35 cubic feet per hour
and is directed around the welding wire for
shielding

Advantages Disadvantages
Welding can be done in all
positions
High rates of metal deposition
Excellent filling ability for
poor-fit joints
High weld Quality
No electrode stub loss
Less distortion due to narrow,
deep weld profile
Easier process to learn and
use
Welding power source
expensive
Shielding gas expensive
Higher electrode wire cost
Most machines require three-
phase input power
Not as versatile as SMAW for
maintenance
Welding cast iron
Cutting
Carbon arc torch
applications
Stationary
Portable
Integrated
Nonintegrated
Advantages and
Disadvantages
Adjustments














Containers
Regulators
Ball and Dial indicators

Gases Materials
Carbon dioxide Steel
Argon Stainless Steel
Helium Aluminum
Oxygen

Types
Integrated
Component
Advantages
Disadvantages

Parts
Feed motor
Drive Assembly
Spool Assembly
Wire speed control
Computer controller

Gun Types
Inline
Handle
Gun
Characteristics
Wire Guide
Tips
Shielding Gas
Nozzle
Insulator
Internal Gun wire
driver


Whip Characteristics
Shielding Gas
Sheath
Liner
Power feed

Wire Types
Hard Wire (Solid)
Dual Shield
Flux Core
Polarity
DCRP
DCSP



Advantages
Disadvantages

Advantages
Disadvantages
TIG Tungsten Inert Gas Welding
TIG
Welding process uses a non-consumable tungsten
electrode to form an arc which is shielded by inert
gas
Filler rod may or may not be used
AC or DC
Argon or Helium gas used
Torch needs current and inert gas to weld
Ceramic cone protects electrode
Air cooled or water cooled

Advantages of TIG
Clean welds no flux
Weld strength is high
All position use
Visibility is high
Narrow beads distortion is low
No Spatter
Weld all weldable metals
Best for Aluminum and Magnesium
Best for thinner metal
Disadvantages of TIG
Skill required more complicated
High Frequency interference may occur
(radios, TVs, etc.)
Inert Gases for Shielding
Argon
Cheap comes from air
Heavier than air blankets
weld well
Provides clean welding of
Aluminum and Magnesium
Best with AC
Helium
Arc voltage is greater
Hotter arc
Deeper Penetration
Fast Speed
Less Distortion
May spatter more than
Argon
Carbon Dioxide
Cooling effect
Low cost
Produces Spatter
Deep penetration
Not same inert
characteristics as Argon and
Helium