MIG Welding

Manufacturing and Materials

Processes

(GMAW) 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

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.

The primary shielding

gasses used are:

Argon
Argon 95% to 5% Oxygen
Argon 75% 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.

Welding Parameters and

Techniques

Welding current
Wire electrode extension
Welding voltage
Arc travel speed

WELDING CURRENT

The welding current is the electrical

amperage in the power system as the weld
is being made.
welding current is directly related to wirefeed speed (if the wire extension beyond
the guide tip is constant). As the wire-feed
speed is varied, the welding current will
vary in the same direction. In other words,
an increase (or decrease) in the wire-feed
speed will cause an increase (or decrease)
of the current.

WIRE ELECTRODE
EXTENSION

Wire extension or stick-out is the

distance between the last point of
electrical contact, usually the end of
the contact tip, and the end of the
wire electrode.

WIRE ELECTRODE
EXTENSION

Controlling tip-to-work distance is

important. Long extensions result in
excess weld metal being deposited
with low arc heat. This can cause
poor bead shape and low
penetration. In addition, as the tipto-work distance increases, the arc
becomes less stable.

WELDING VOLTAGE

voltage setting directly controls the

arc length.
In addition, a certain range is
required to maintain arc stability at
any given welding current level.

ARC TRAVEL SPEED

As the material thickness increases,

the travel speed must be lowered.
For a given material thickness and
joint design, as the welding current is
increased, so is the arc travel speed.
The converse is also true.
Higher welding speeds are attainable
by using the forehand welding
technique.

WELDING TECHNIQUES

Torch Position
Split the angle (90 degrees = 45 degree
split)
5 degree rake

Good
Weld

Voltage to
High

Voltage to
Low

Too Fast

Too Slow

Less Stick
Out