GAS METAL ARC WELDING

Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert
which an electric arc forms between a consumable wire electrode and the work piece
metal(s), which heats the work piece metal(s), causing them to melt and join.

MIG welders consist of

a handle with a trigger controlling a wire feed
Feeding the wire from a spool to the weld joint.

The wire is similar to an endless bicycle brake cable. The wire runs through the liner,
which also has a gas feeding through the same cable to the point of arc, which
protects the weld from the air .MIG welding is most commonly used in fabrication
shops where production is high, and the possibility of wind blowing away your gas
shielding is unlikely.

How MIG Welding Works

MIG weld welding requires three things, electricity to produce heat, an electrode to
fill the joint, and shielding gas to protect the weld from the air. MIG welding is done
using a very small electrode that is fed continuously, while the operator controls the
amount of weld being done. In some cases when a robot takes over this process, it
becomes automatic welding.

Voltage Type and Welding Polarity

 MIG welding unlike most other welding processes has one standard voltage type and
polarity type. The voltage used is D/C direct current, much like the current in a car
battery. Direct current flows in one direction, from the negative (-) to the positive (+).

The power source used for MIG welding is called a constant voltage power supply.
In MIG welding the voltage is what is controlled and adjusted.

MIG Electrode Types

Typical MIG welding electrodes are a solid wire ranging from a thickness of .023 to .
045. Some are much thicker for heavy industrial applications. The most common
sizes are:

.023
.030
.035
.045

The most common wire used for welding carbon steel is ER 70S-6. In some cases
you can weld two different metals together. An example of this is welding 304
stainless steel to A36 carbon steel using an electrode made of 309 stainless steel
ER 309L.

The manufactures of these electrodes use a standard code to identify the type of
electrode. For example the code on the label ER 70S-6 represents the following:
ER An electrode or filler rod that is used in either a wire feed or TIG welding.
70 A minimum of 70,000 pounds of tensile strength per square inch of weld.
S -Solid wire.
6 The amount of deoxidizing agent and cleansing agent on the electrode.

MIG Welding Gasses

MIG welding requires a shielding gas to be used. As the name states Metal Inert
Gas Welding there is no shielding on the electrode or filler wire. MIG welding would
not be possible without shielding gas. The way the shielding gas works is it is feed
through the MIG gun and it literally suffocates the weld area from any air. This
provides an air free zone where the welding arc and filler wire can do their work to
get the joint welded.

MIG welding typically three types of gas for shielding and they are:

Argon
Carbon Dioxide
Helium
 These three gases are typically used as a mixture depending on the metals that are
being welded. The shielding gas needs to be matched to the electrode and base
metal. If they are not compatible then the welds will either not be strong or it just
wont weld properly.

The type of gas uses also determines:

How deep the weld penetrates the metal welded

The characteristics of the welding arc
The mechanical properties of the weld.

Transfer Types
MIG welding has four ways of transferring the wire to the joint.

Short circuit
Globular
Spray
Pulsed spray

The transfer types used to MIG weld are determined by the metal type, shielding gas
used and machine settings. MIG welding transfer types are more of a machine set-
up issue then a welding issue.

Almost any metal may be MIG Welded

MIG welding is a welding process that can weld almost any metal. It may not always
be the best choice for weld quality but MIG welding is a fast, cost efficient, and
produces results that are more than acceptable for most manufacturing and
fabrication needs! Not everybody is building a space station. The three most
common metals welded with a MIG welder are:

Carbon steel.
Stainless steel.
Aluminium, with a special feeder because aluminium wire is very soft.