Mig Mag Welding

MIG/MAG &
Flux Cored Arc Welding
Koray YURTIIK
yurtisik@gmail.com
yurtisik@metu.edu.tr
Review of Part I and II

Definition
Advantages
Disadvantages
Application Fields
Equipment
Filler Metals (Wire electrodes)
Shielding Gases
Internal Control System (Principle)
Forces acting on the Arc
Types of Arc
Setting-up of a MIG/MAG Welding Unit
Welding Parameter Influences
Pulsed Arc
Possible Defects when MIG/MAG Welding
Weld Bevel Preparation
Backing
Content
MIG/MAG & Flux Cored Arc Welding, 2 of 85
Definition
A fixed composition of gas shields the weld metal.

Filler metal is an electrode at the same time (a
difference w.r.t. TIG)
Filler metal is continuous ( a difference w.r.t. TIG &
MMA)
Naturally born Semi-mechanized
DCEP (reverse polarity),
DCEN is seldom used because of poor transfer
of molten metal from the wire electrode to the
workpiece.
Advantages
All positions are available
Less and sometimes even no slag removal (manhour),
Metal Deposition Rate is high,
Fast (2 times more than MMA),
Less distortion,
Low cost filler metal (w.r.t. MMA & UP)
Disadvantages
Lack of Fusion
At start
Filler metal melts on to cold
substrate
When low linear welding speed
Weld pool flowing in front of the arc
Sensitive to environmental conditions
Constructional steel or aluminum members,

Shipyards,
Automotive,
Pipe Lines,
Pressure Vessels and Processing Equipments,
Heat Exchangers, Boilers, Piping
Fields of Application
Power supply
Wire feed unit
Hose assembly
Torch
Blowtorch
Equipment
Power Supply
Blow torch
Vessel of
Shielding gas
With transistor inverter
With transistor rectifier
Wire feed unit
Neutral cable
Hose assembly
Power supply
Torch
Work piece
Wire electrode
Arc
Constant potential power supply

The potential change between 3 to 5 Volts corresponds to current amplitude of 100 A
Self correcting arc
Kural olarak g elemanlar ayarlanabilen endktansa sahiptir.
Endktans kaynak akmndaki sapmalar azaltr ve akm art hzn deitirir. rnein tutuma
srasnda hzl bir akm art avantajlyken, ksa devreyle ark srasnda yava bir akm art daha az
srant oluturur.
Types;
Conventional
With Trystor
1.5 m/min 20 m/min
Wire Feed Unit
1.5 m/min 20 m/min
Wire Feed Unit
One or more than one driving unit

are possible
Wire Feed Unit
Wire Feed Unit
Hose Assembly
Carries;
Cooling air (lower
than 250 A) or
water,
Wire electrode,
Shielding gas,
Welding current and
potential.

Torch
(4)
(3)
(2)
(1)
Nozzle output face
Contact tip,
Shielding gas diffuser,
Moulded phenolic dielectric (shown in white)

and threaded metal nut insert (yellow),
Torch handle,
(5)
[Reference: Mysid, TTlightningRod]

Wire Electrodes
Solid
Wire Electrodes
Flux Cored
Cruf zl
Less welding current for the

same metal deposition rate.
Metal zl
Rutile
Basic
Stainless Steel
Wire Electrodes
C-steel
ISO 17633
Wire Electrodes for Steels
Stainless Steel
ISO 17632
Flux Cored
C-steel
ISO 14343
Solid
ISO 14341
Wire Electrodes
ISO 14341
Wire Electrodes
ISO 14341
Wire Electrodes
ISO 14341
Wire Electrodes
ISO 14341
Wire Electrodes
ISO 14341
Wire Electrodes
ISO 14341
Wire Electrodes
ISO 17632 -
Wire Electrodes
ISO 17632 -
Wire Electrodes
ISO 17632 -
Wire Electrodes
ISO 17632 -
Shielding Gases
Shielding Gases
Plain carbon, low-alloyed and high-alloyed steels except stainless steels

M2, M3 & C
Stainless steels
M1
Aluminium, Titanium, Magnesium
I
Nickel and its alloys
I & M1
Shielding Gases
Shielding Gases
Spatter
Pinch effect;
An electromagnetic force
Proportional to the square of current amplitude, I
Surface tension;
Oxide patches on the droplet reduse the surface
tension
The higher surface tension, the bigger droplets
Metals evaporating;
Pressure against to the droplet
Plasma beam;
Gravitation;
Forces in Arc and on to the Droplet
Process Variations Metal Transfer
Metal is transferred from the wire to the weld

pool only when contact between the two is
made, or at each short circuit.
The wire short circuits to the work piece 20 to
200 times per second
Uses small wire in the range of .8 to 1.2 mm
diameter
Operates at low arc lengths (low voltages) and
welding currents
Fast-freezing weld puddle is obtained
This welding technique is particularly useful for
joining
thin materials in any position,
thick materials in the vertical and
overhead position,
and for filling large gaps
Short arc welding should also be used where
minimum distortion of the work piece is a
requirement because of its low heat input
C, M2 and M3 gases.
Hard to control and easy to leave defect.
Short Circuit Transfer (Short Arc) Welding [15

20 V]

20%
100% CO2
100% Ar
Surface
tension
20
150
20
Metal transferring through the arc,

Usually, the drops of molten metal have a
greater diameter than the wire itself,
The metal transfer with spatter and
occasional short circuiting,
Occurs with gases consisting more than
20% CO2,
Such gases have good thermal
conductivity, so the interface between the
electrode and the arc is very narrow,
No use for hard welding positions,
Metal transfer efficiency is very low, in
between 87 and 93%,
Lack of fusion risk is very high.
Globular Transfer (Long Arc) Welding [ > 20

V]:

150
The molten drops from the wire are very small,

affording good arc stability, short circuiting is rare.
Little spatter, high deposition rates of weld metal,
more than 98%.
3 mm and greater in thickness
The minimum welding current at which this occurs is

called the transition current, above the transition
current pinch effect becomes effective.
The transition current depends on the metal wire
diameter and shielding gas.
However, if the shielding gas for welding carbon steel
contains more than about 20% CO2 there is no
transition from globular transfer to spray transfer.
Spray arc [higher than 25 V]:

By raising the welding current and voltage still
further, the metal transfer will become a true spray
arc.

Spray arc
20
20
150
150
The low level of current is below the transition current while the high level is well into the spray arc region.
Usually one droplet is transferred during each high current pulse.
The peak current is in the spray arc region, arc stability is similar to that of conventional spray arc welding.
Producing a spray arc at lower average current levels than are required for conventional spray arc welding.
The lower average current makes it possible to weld thinner gauge materials with spray type transfer
It can also be used for out-of-position welding of heavier sections.
LWS of 1.2 meter per minute.
The period of low current maintains the arc and serves to reduce the average current.
Metal is only transferred to the work during the period of high current.
Pulsed Arc;
A variation of the spray arc technique is known as pulsed spray welding.
The current is varied between a high and low value.
Pulsed Arc
Pulsed Arc
V1, I1
V
V1, I1
V2, I2
(V1) (I1) = P = (V2) (I2)
V-I Characteristics for Power Supply
5V
100 A
V2, I2
V-I Characteristics for the Arc
Maximum possible arc length
V-I Characteristics for the Arc
V=IR
R=L/A
Long arc lengths

Optimum arc length
Stable Arc Zone
Short arc lengths
Minimum possible arc length
V-I Characteristics for Power Supply

Constant potential characteristics
V-I Characteristics for Power Supply and for the Arc
(Nearly) Constant Potential

3 V 100 A
V
V2
V1
I2
100 A
3V
Constant potential
Constant wire feed speed
WFS
I
Melting Rate
I
I1
I
200 A
5.6 m/dk
4.3 m/dk
150 A
5.6 m/dk
5.6 m/dk
200 A
5.6 m/dk
6.8 m/dk
250 A
5.6 m/dk
5.6 m/dk
200 A
5.6 m/dk
250 A
5.6 m/dk
150 A
Internal Control System (Self Correcting Principle) in MIG/MAG
200 A
The single switch

operation
Simple power supplies

show two buttons for the
arc set-up;
the voltage and
the wire feed.
Better equipped welding
units also contain an
adjustable inductivity
(valve).
An increasing wire feed

velocity always requires a
higher arc voltage.

arc set-up;
the voltage and
the wire feed.
(valve).

arc set-up;
the voltage and
the wire feed.
(valve).

arc set-up;
the voltage and
the wire feed.
(valve).

arc set-up;
the voltage and
the wire feed.
(valve).

arc set-up;
the voltage and
the wire feed.
(valve).

arc set-up;
the voltage and
the wire feed.
(valve).

arc set-up;
the voltage and
the wire feed.
(valve).
Changing the voltage while WFS is

constant:
Length of the arc and weld profile
change,
The current and and the rate of
deposition remain constant.
The arc voltage determines the arc

length and therefore the seam width.
High V flat and wide seam
Undercuts such as inconvenient seam
changes can occur because of the
magnetic blow effect.
If the arc is too long alloy elements can
be combusted in the arc and the smoke
formation raises.
Low V narrow and strongly
reinforced seams
Short-circuits.
Changing the voltage while WFS is

constant:
Length of the arc and weld profile
change,
The current and and the rate of
deposition remain constant.
The arc voltage determines the arc

length and therefore the seam width.
High V flat and wide seam
Undercuts such as inconvenient seam
changes can occur because of the
magnetic blow effect.
If the arc is too long alloy elements can
be combusted in the arc and the smoke
formation raises.
Low V narrow and strongly
reinforced seams
Short-circuits.
Changing the WFS while

retaining the voltage constant:
Length of the arc, weld profile, the
current and and the rate of
deposition change.
WFS the deposition

efficiency, the welding
amperage.
A raising wire speed increases the
amperage and the penetration
depth.
The seam width is barely
influenced. The seam
reinforcement raises because of
the increased deposition
Efficiency if LWS is constant.
Combinations of V and WFS
The connection between a wire

electrode with a thickness of 1.2 mm
and different shielding gases:
CO2 mixed gases and argoncontaining mixed gases with
higher amounts of CO2 demand
an increased arc voltage which
contrasts argon mixed gases or
mixed gases with a high amount
of argon containing less than
20% of CO2.
Positioning the Welding Torch
Positioning the Welding Torch
At constant welding data, the higher LWS, the narrower seam cross section.
The ergonomic manual welding velocities are at between 40 and 60 cm/min:
Is the welding speed reduced to values below 40 cm/min, a molten pool running ahead of the welding area
can strongly reduce the penetration with poor fusion as a result.
It is better to quickly weld a seam in three layers than to slowly weld it in only one.
Usually for series productions are welding velocities of 1 1.5 m/min.
At too high speed undercuts can occur and the weld turns out to be reinforced and narrow.
Linear Welding Speed, LWS
Setting-up of the Pulsed MIG/MAG
Five setting points are needed to correctly set up the metal transfer:
wire speed,
impulse frequency,
pulse width,
pulse height, and
background current height.
The pulse width and height is to select in order to achieve an arc with low spatter formation and no shortcircuits.
Advantages:
Low spatter,
Flatter beads,
Better seam shape,
Lower heat input.
Disadvantages:
Higher investment cost,
Setting-up is diffucult,
Good wire quality is needed,
Gap-bridging ability is poor.
Cracking
Porosity
Lack of Fusion
Spatter
Unfavorable Seam Geometry
Possible Welding Defects
When the thickness of the reinforcement is

too much.
When there is Hi-Low on Fit-up.
When the root face is too high or root opening

is too low.
When weld bevel angle is less than enough

(60 degrees total).
Lack of Fusion
It is possible that the first drops transferring in
the arc meet an incompletely molten base
material. The drop energy itself is not enough
to melt the base material. The drop lays
without any fusion to the base material.
Wrong torch positioning.
Restricted welding access.
Wrong bead sequence or placement.
When molten pool is running ahead of the arc

due to too LWS, improper torch inclination.
Lack of Fusion
Too low arc power, too much LWS and too
high torch spacing or arc length.

Lack of Fusion

Lack of Fusion

Lack of Fusion

Lack of Fusion
Nitrogen on edges cut by laser, plasma.
Cavities.
Contamination.
Inappropriate shielding gas.
Too long arc.
Draught.
Magnetic blow effect.
Porosity
Dirts and defects on the torch.
Cavities.
Contamination.
Too long arc.
Draught.
Porosity
Cavities.
Contamination.
Too long arc.
Porosity
Cavities.
Contamination.
Too long arc.
Draught.
Porosity
Cavities.
Contamination.
Too long arc.
Porosity
Cavities.
Contamination.
Too long arc.
Porosity
Cavities.
Contamination.
Too long arc.
Porosity
Cavities.
Contamination.
Too long arc.
Porosity
Cavities.
Contamination.
Too long arc.
Porosity
Finalizing
Steel
Weld Bevel
Aluminium
Weld Bevel
> 60o
3-4
1-2
Backing

Mig Mag Welding

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MIG/MAG &

Flux Cored Arc Welding

Review of Part I and II

MIG/MAG & Flux Cored Arc Welding, 2 of 85

A fixed composition of gas shields the weld metal.

Constructional steel or aluminum members,

MIG/MAG & Flux Cored Arc Welding, 3 of 85

MIG/MAG & Flux Cored Arc Welding, 4 of 85

With transistor inverter

With transistor rectifier

Wire feed unit

MIG/MAG & Flux Cored Arc Welding, 5 of 85

Constant potential power supply

MIG/MAG & Flux Cored Arc Welding, 6 of 85

1.5 m/min 20 m/min

Wire Feed Unit

1.5 m/min 20 m/min

Wire Feed Unit

MIG/MAG & Flux Cored Arc Welding, 7 of 85

MIG/MAG & Flux Cored Arc Welding, 8 of 85

One or more than one driving unit

Wire Feed Unit

Wire Feed Unit

MIG/MAG & Flux Cored Arc Welding, 9 of 85

MIG/MAG & Flux Cored Arc Welding, 10 of 85

Nozzle output face

Shielding gas diffuser,

Moulded phenolic dielectric (shown in white)

MIG/MAG & Flux Cored Arc Welding, 11 of 85

[Reference: Mysid, TTlightningRod]

Less welding current for the

MIG/MAG & Flux Cored Arc Welding, 13 of 85

Wire Electrodes for Steels

MIG/MAG & Flux Cored Arc Welding, 14 of 85

MIG/MAG & Flux Cored Arc Welding, 15 of 85

MIG/MAG & Flux Cored Arc Welding, 16 of 85

MIG/MAG & Flux Cored Arc Welding, 17 of 85

MIG/MAG & Flux Cored Arc Welding, 18 of 85

MIG/MAG & Flux Cored Arc Welding, 19 of 85

MIG/MAG & Flux Cored Arc Welding, 20 of 85

MIG/MAG & Flux Cored Arc Welding, 21 of 85

MIG/MAG & Flux Cored Arc Welding, 22 of 85

MIG/MAG & Flux Cored Arc Welding, 23 of 85

MIG/MAG & Flux Cored Arc Welding, 24 of 85

MIG/MAG & Flux Cored Arc Welding, 25 of 85

MIG/MAG & Flux Cored Arc Welding, 26 of 85

MIG/MAG & Flux Cored Arc Welding, 27 of 85

Plain carbon, low-alloyed and high-alloyed steels except stainless steels

MIG/MAG & Flux Cored Arc Welding, 28 of 85

Forces in Arc and on to the Droplet

Process Variations Metal Transfer

Metal is transferred from the wire to the weld

Short Circuit Transfer (Short Arc) Welding [15

MIG/MAG & Flux Cored Arc Welding, 29 of 85

MIG/MAG & Flux Cored Arc Welding, 30 of 85

Process Variations Metal Transfer

Process Variations Metal Transfer

Metal transferring through the arc,

Globular Transfer (Long Arc) Welding [ > 20

MIG/MAG & Flux Cored Arc Welding, 31 of 85

MIG/MAG & Flux Cored Arc Welding, 32 of 85

Process Variations Metal Transfer

The molten drops from the wire are very small,

The minimum welding current at which this occurs is