GMAW / Mig Welding

Basic equipment setup and welding procedures

Gas Metal Arc Welding

Is a process where a continuously fed metal electrode ( Wire ) contacts the base metal and produces heat . The arc is shielded by an inert gas

GMAW Components
DC or Direct Current power supply Electrode or wire feed controller Wire drive roller assembly Shielding gas source (cylinder) & regulator

Manually held Gun & ground clamps

Wire reel

GMAW component diagram

Gas Metal Arc Welding Principles

Gas metal arc welding is generally used

due to the high efficiency of filler metal that can be deposited per hour.
GMAW is approximately 92% - 98% efficient GMAW requires a shielding gas

Gas Metal Arc Welding Principles

The GMAW process is performed using

DCEP ( Direct Current Electrode Positive)

Alternating current is never used for GMAW for a specialized process using emissive electrodes

DCEN is used only

GMAW Advantages

Welding can be done in all positions No slag removal required High efficiency Less work piece distortion Large gaps bridged easily , Good for poor fitup High Weld Quality

Typical Setup for voltage

The GMAW machine is a Constant Voltage power supply. This is set using the voltage dial This setting can be monitored by the Volt meter on the front panel of the welder Ideal voltage settings can be found in the wire manufactures data book

Typical Setup for Wire speed

The wire feed rate or speed is set using the dial on the wire controller This setting increases or decreases current or Heat. This setting is measured in AMPS or IPM (inches per minute ) Ideal settings can be monitored by the Amp meter on the front panel of the welder. Note : Some machines display Current (Same as AMPS) or IMP Ideal settings can be found in the wire manufactures data book for both IPM and Current

Shielding Gas

Air in the welding zone is displaced by inert gas to Shield the molten weld pool and prevent it from contamination from Oxygen, Nitrogen and Water present in the atmosphere. Insufficient gas flow will not displace the atmosphere resulting in porosity or voids in the deposited weld. Flow is measured in CFH (Cubic Feet per Hour).

Insufficient Shielding Gas coverage

Gas not turned on Flow rate not properly adjusted Leaks in the hose supplying the shielding gas to the machine GMAW / MIG Gun loose at wire drive connection Spatter buildup on gas cup Windy environment

Excessive Gas coverage

Will cause porosity. The turbulence caused by the rapid flow of shielding gas exiting from the gas cup will draw the surrounding atmosphere into the stream of gas. It will reduce weld pool temperatures causing decreased penetration .

Check the Manufactures data for settings