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    Fundamentals MIG Welding

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    Sreejith Menon
    The document discusses key factors for successful MIG welding: 1) Selection of correct consumables such as welding wire, shielding gas, and power source suited to the material and thickness. 2) Applying proper welding techniques such as maintaining the correct electrical stick-out, travel speed, and torch angle depending on the weld joint type. 3) Choosing the appropriate shielding gas depending on the material, with thicker materials generally requiring higher CO2 content in the gas mixture.

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    Fundamentals MIG Welding

    Uploaded by

    Sreejith Menon
    89 views3 pages
    The document discusses key factors for successful MIG welding: 1) Selection of correct consumables such as welding wire, shielding gas, and power source suited to the material and thickness. 2) Applying proper welding techniques such as maintaining the correct electrical stick-out, travel speed, and torch angle depending on the weld joint type. 3) Choosing the appropriate shielding gas depending on the material, with thicker materials generally requiring higher CO2 content in the gas mixture.

    Original Description:

    Fundamentals of Metal Inert Gas welding.

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    The document discusses key factors for successful MIG welding: 1) Selection of correct consumables such as welding wire, shielding gas, and power source suited to the material and thickness. 2) Applying proper welding techniques such as maintaining the correct electrical stick-out, travel speed, and torch angle depending on the weld joint type. 3) Choosing the appropriate shielding gas depending on the material, with thicker materials generally requiring higher CO2 content in the gas mixture.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    89 views3 pages

    Fundamentals MIG Welding

    Uploaded by

    Sreejith Menon
    The document discusses key factors for successful MIG welding: 1) Selection of correct consumables such as welding wire, shielding gas, and power source suited to the material and thickness. 2) Applying proper welding techniques such as maintaining the correct electrical stick-out, travel speed, and torch angle depending on the weld joint type. 3) Choosing the appropriate shielding gas depending on the material, with thicker materials generally requiring higher CO2 content in the gas mixture.

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    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
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    of 3

    8

    Consumables

    Fundamentals of Metal Inert Gas (MIG) Welding


    Welding Technique
    Successful welding depends on the following factors: 1 Selection of correct consumables 2 Selection of the correct power source 3 Selection of the correct shielding gas 4 Selection of the correct application techniques: a Correct angle of electrode to work b Correct electrical stick-out c Correct travel speed 5 Selection of the welding preparation. Material
    AS2074 C1, C2, C3, C4-1, C4-2, C5, C6 AS/NZS 3678-9 250, 300, 350, 400 AS1548-430, 460, 490 ASTM A36, A106 Stainless Steel Grade 304 Stainless to Carbon-Mn steels Grade 316 Aluminium 1080 6061, 3004 5005 BOC Aluminium MIG 1080 BOC Aluminium MIG 4043 BOC Aluminium MIG 5356 BOC Stainless Steel 316LSi BOC Stainless Steel 308LSi

    Common Materials Welded with BOC MIG Wire BOC MIG Wire
    BOC Mild Steel MIG Wire BOC Mild Steel MIG Wire BOC Mild Steel MIG Wire BOC Mild Steel MIG Wire

    Selection of correct consumables


    Chemical composition As a general rule, the selection of a wire is straightforward, in that it is only a matter of selecting an electrode of similar composition to the parent material. However, there are certain applications for which electrodes will be selected on the basis of mechanical properties or the level of residual hydrogen in the weldmetal. Solid MIG wires are all considered to be of the low hydrogen type consumables. The following table gives a general overview of some of the BOC range of MIG wires for the most common materials. More detailed selection charts for specific materials can be found in the appropriate materials sections. Material
    Mild and Alloy steel Quench and tempered steels Ferritic materials Stainless steel Aluminium

    Physical condition Surface condition. The welding wire must be free from any surface contamination, including mechanical damage such as scratch marks. A simple test for checking the surface condition is to run the wire through a cloth that has been dampened with acetone for 20sec. If a black residue is found on the cloth, the surface of the wire is not properly cleaned. Cast and Helix. The cast and helix of the wire has a major influence on the feedability of MIG wire.

    Page No
    351 353 352 406 425

    Cast
    Helix

    WARNING W elding can give rise to electric shock, excessive noise, eye and skin burns due to the arc rays, and a potential health hazard if you breathe in the emitted fumes and gases. Read all the manufacturers instructions to achieve the correct welding conditions and ask your employer for the Materials Safety Data Sheets. Refer to www.boc.com.au or www.boc.co.nz

    318

    AU : IPRM 2007 : Section 8 : consumables

    Fundamentals of Metal Inert Gas (MIG) Welding


    Cast Diameter of the circle Helix Vertical height If the cast is too small, the wire will dip down from the tip. The result of this is excessive tip wear and increased wear in the liners. If the helix is too large, the wire will leave the tip with a corkscrew effect and cause feeding problems. Different grades of shielding are required for materials such as stainless steel, aluminium and copper. The following table gives an indication of the most common shielding gases used for carbon manganese and alloy steels: Material thickness
    18mm 512mm >12mm

    Recommended shielding gas


    Argoshield Light Argoshield Universal Argoshield Heavy

    Selection of the Correct Power Source


    Power sources for MIG/MAG welding is selected on a number of different criteria, including: 1 Maximum output of the machine 2 Duty cycle 3 Output control (voltage selection, wire feed speed control) 4 Portability The following table gives an indication of the operating amperage for different size wires Wire Size
    0.8mm 0.9mm 1.0mm 1.2mm

    More detailed selection charts, including recommendations for welding parameters (voltage, amperage, electrical stick-out, travel speed and gas flow rate) can be found in the following sections: Material
    C-Mn and Alloy Steels Argoshield Light 60 61 62 63

    Page

    Amperage Range (A)


    60180 70250 90280 120340

    Argoshield Universal Argoshield Heavy Argoshield 52 Stainless Steel Stainshield Stainshield Heavy Aluminium Argon Alushield Light Alushield Heavy Copper Specshield Copper

    65 65

    A BOC power sources selection chart is contained in the arc equipment section of this manual (see pages 240241).

    Selection of the Correct Shielding Gas


    The selection of the shielding gas has a direct influence on the appearance and quality of the weldbead. The type and thickness of the material to be welded will determine the type of shielding gas that is selected. As a general rule, the thicker the material (C-Mn and Alloy Steels), the higher the percentage of CO2 in the shielding gas mixture.

    54 67 67

    80

    Wire Operating Limits


    35
    Undercutting and burnback

    30
    1.0mm 1.2mm

    Spray Transfer Optimum Parameters DipTransfer Optimum Parameters Defect Free Zone

    25

    Burnback and arc instability

    Voltage (V)

    20
    0.8mm

    0.9mm

    1.0mm

    Electrode (wire) stubbing and spatter Defect Zone

    15
    No working condition
    0 1 2 3 4 5 2 3 4 5

    10

    Dip Transfer (Steel Thickness (mm)) 0 1

    Spray Transfer (Steel Thickness (mm))

    50

    100

    150

    200

    250

    300

    350

    400

    Current (A)
    WARNING W elding can give rise to electric shock, excessive noise, eye and skin burns due to the arc rays, and a potential health hazard if you breathe in the emitted fumes and gases. Read all the manufacturers instructions to achieve the correct welding conditions and ask your employer for the Materials Safety Data Sheets. Refer to www.boc.com.au or www.boc.co.nz

    AU : IPRM 2007 : Section 8 : consumables

    319

    Fundamentals of Metal Inert Gas (MIG) Welding


    Torch position for fillet welds

    Correct Application Techniques


    Direction of welding MIG welding with solid wires takes place normally with a push technique. The welding gun is tilted at an angle of 10 towards the direction of welding (push technique).

    When welding fillet welds, the torch should be positioned at an angle of 45 from the bottom plate, with the wire pointing into the fillet corner. Welding is still performed in the push technique Electrical stick-out
    1 2 3 4 5 6 7 8 9 9 Gas Nozzle Contact Tube Setback Consumable Electrode Workpiece Standoff Distance Contact Tube Visible Stick-out Arc length Electrical Stick-out

    1 2

    The influence of changing the torch angle and the welding direction on the weld bead profile can be seen below

    3 5

    7 8

    The electrical stick-out is the distance between the end of the contact tip and the end of the wire. An increase in the electrical stick-out results in an increase in the electrical resistance. The resultant increase in temperature has a positive influence in the melt-off rate of the wire that will have an influence on the weldbead profile Torch perpendicular to workpiece Narrow bead width with increased reinforcement
    10

    Short

    Normal

    Long

    Influence of the change in electrical stick-out length on the weldbead profile Torch positioned at a drag angle of 10 narrow bead with excessive reinforcement
    015

    Travel speed

    Slow
    90 90

    Normal

    Fast

    The travel speed will influence the weldbead profile and the reinforcement height. If the travel speed is too slow, a wide weldbead with excessive rollover will result. Conversely, if the travel speed is too high, a narrow weldbead with excessive reinforcement will result. Recommendations for travel speed are contained in the detailed gases datasheets found in pages 5868 of this manual.

    Torch position for butt welds

    When welding butt welds, the torch should be positioned within the centre of the groove and tilted at an angle of 15 from the vertical plane. Welding is still performed in the push technique

    WARNING W elding can give rise to electric shock, excessive noise, eye and skin burns due to the arc rays, and a potential health hazard if you breathe in the emitted fumes and gases. Read all the manufacturers instructions to achieve the correct welding conditions and ask your employer for the Materials Safety Data Sheets. Refer to www.boc.com.au or www.boc.co.nz

    320

    AU : IPRM 2007 : Section 8 : consumables

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