Objective

To learn MIG (metal inert gas) welding theoretically and practically.

To learn about technique of MIG(metal inert gas) welding in fillet (t-joint)

To know about advantages, disadvantages and application of MIG (metal inert gas)
welding

Theory
Power source
MIG welding is carried out on DC electrode (welding wire) positive polarity (DCEP).
However DCEN is used (for higher burn off rate) with certain self- shielding and gas
shield cored wires. DC output power sources are of a transformer-rectifier design, with a
flat characteristic (constant voltage power source). The most common type of power
source used for this process is the switched primary transformer rectifier with constant
voltage characteristics from both 3-phase 415V and 1-phase 240V input supplies. The
output of direct current after full wave rectification from a 3-phase machine is very
smooth. To obtain smooth output after full wave rectification with a 1- phase machine, a
large capacitor bank across the output is required. Because of the expense of this, many
low cost 1-phase machines omit this component and therefore provide a poorer weld
characteristic. The switches to the main transformer primary winding provide the output
voltage steps at the power source output terminals. Another method of producing
different voltages at the power source output terminals is to use a Thyristor or a
Transistor rectifier instead of a simple diode rectifier. This system offers continuously
variable output voltage, which can be particularly useful on robot installations and the
cost of this type of rectifier can be partly offset with no need for primary voltage switch
or switches and a single tapped main transformer primary winding. Most MIG power
sources have a contactor or relay used to switch the output ON/OFF with operations of
the trigger on the MIG torch. The switch off operation of this contactor is normally
delayed to allow the welding wire to Burn back out of

the molten weld pool. A

thermostat is fitted on the hottest point in the power source, in series with the contactor
coil to provide thermal protection to the machine. Power source performance is measured

by its ability to provide a certain current for a percentage of a 10 minute period before
Thermal Cut Out. This is the Duty Cycle.

The Wire-feed Unit

The wire-feed unit, or sub-assembly where this is mounted in the power source cabinet
(known as a composite MIG), provides the controlled supply of welding wire to the point
to be welded. According to the welding wire size and arc voltage provided by the power
source, a constant rate of wire speed is required, in MIG welding the power source
provides Arc voltage control and the wire feed unit provides welding wire speed control,
( in MIG this equates to welding current ). Most modern wire feed units control the wire
feed speed via a DC motor and thyristor control PCB to provide continuos control of
Armature volts and hence RPM of motor. The wire feed motor spindle has a feed roller
fitted and another pressure roll, adjustable spring mounted to lightly grip the
wire and push it up the length of the MIG torch.

Welding Process Variables

During a manual welding operation, the welder has to have control over the welding
variables, which affect the weld penetration, bead geometry and the overall weld quality.
A proper selection of welding variables will increase the chances of producing welds of a
satisfactory quality. However, these variables are not completely independent and
changing one variable generally requires the changing of some of the others in order to
achieve the desired result. When all these variables are in proper balance, the welder can
deposit higher quality weld metal and produce sound welds. The selection of the welding
variables should be made after the base metal, filler metal and joint design have been
determined. The welding process variables mainly affect the geometry of the weld bead
such as the penetration, bead reinforcement, bead width and the deposition rate, which is
the weight of the metal deposited per unit of time. These variables are as follows:

Welding Current

Travel speed

Welding voltage

Type of shielding gas

Electrode angle

Wire electrode size

Weld joint position

Electrode extension

Metal Transfer Across The Arc

Short circuiting transfer
In short-circuit transfer, the electrode touches the work and short circuits, causing the metal
to transfer as a result of the short. This happens at a rate of 20 to more than 200 times per
second. The advantage of the short-circuit transfer is its low energy. This method is
normally used on thin material inch or less, and for root passes on pipe with no backing.
It can be used to weld in all positions.
Globular transfer
Globular transfer mode happens when a molten droplet is formed on the end of the electrode
then drops off due to gravity or from short circuiting. This droplet has to be at a larger
diameter than the electrodes diameter to be considered globular transfer.
Spray transfer
Spray transfer is named for the spray of tiny molten droplets across the arc. Spray transfer
usually is smaller than the diameter of the wire and uses relatively high voltage and wire
feed speeds or amperage. Unlike short-circuit transfer, once the arc is established, it is on at
all times. This method produces very little spatter and is most often used on thick metals in
the flat and horizontal positions
Pulsed spray transfer
A type of metal transfer in which as little as one droplet of metal forms on the end of the
electrode during periods of high current, but ceases during periods of low current. Pulsed
spray welding reduces the heat input to the base metal, which makes it easier to weld thin
aluminum with GMAW.

Advantages & Disadvantages

Advantages
This process is easy to learn. Within a short period of time, you can become pretty good at
quality welds. Cleanup from a welding session is minimal. The next advantage of MIG
welding is its speed. In MIG welding process, you need not change rods because a solid
continuous wire is used. As compared to other welding processes, quality welds can be
produced faster by this method. MIG welding enables you to achieve a higher output of work
compared to other types of welding. The elimination of flux in MIG welding helps to prevent
slag defects in the weld. You can easily weld thick and thin, both types of workpieces
effectively The shield gas protects the arc. So you need not replace the electrode frequently.
This also helps to put a stop to weld splatter. This process can be applied on different metals
including stainless steel, mild steel and aluminum. Your weld deposition rate will be higher
as compared to other alternative processes The MIG welding process can be either manual or
automated. This process enables you to produce joints with deep penetration. The process can
be easily mechanized. The welded surfaces produced by this method are smooth, clean and
spatter free.

Disadvantages
The MIG welding process does not work well in outdoor welding applications because air
drafts may disperse the shielding gas. In this process, the weld metal cooling rates are higher
as compared to processes that deposit slag over the weld metal. Furthermore, this process
requires a Wire Feeder which is difficult to move and can sometimes be a maintenance /
repair burden and welding gun is difficult to get into tight places as well.

Tools & Equipment

Personal protective equipment

Welding - Personal Protective Equipment
Body Part
Eyes
face

Equipment

and Welding
helmet, hand
shield,
or
goggles

Illustration

Reason
Protects from:

radiation

hot slag, sparks

intense light

irritation
and
chemical burns

Wear fire resistant head

coverings under the
helmet
where
appropriate
Exposed
skin (other
than feet,
hands, and
head)

Fire/Flame
resistant
clothing and
aprons

Feet and Boots,

hands
gloves

Protects against:

heat, fires

burns

Notes: pants should not

have cuffs, shirts should
have flaps over pockets
or be taped closed
Protects against:

electric shock

heat

burns

fires

Welding equipment

Torch & Accessories

The welding torch guides the wire and shielding gas to the weld zone.
Brings welding power to the wire as well
Major components/parts of the torch are the contact tip, shielding gas nozzle, gas
diffuser, and the wire conduit

Welding Control &Wire Feed Motor

Welding control & Wire feed motor are combined into one unit
Main function is to pull the wire from the spool and feed it to the arc
Controls wire feed speed and regulates the starting and stopping of wire feed
Wire feed speed controls Amperage

Power Source (welding machine)

Almost all GMAW is done with reverse polarity also known as DCEP
Positive (+) lead is connected to the torch
Negative (-) lead is connected to the work piece
Provides a relatively consistent voltage to the arc
Arc Voltage is the voltage between the end of the wire and the work piece

Wire Brush

Wire brush is used for cleaning rust

It is used to clean surfaces and to create a better conductive area
for attaching electrical connections.

Plier

Hand tool used to hold objects firmly (hot object such as weld
metal)

Shielding Gases

Purpose of shielding gas is the protect the weld area from the contaminants in the
atmosphere
Gas can be Inert, Reactive, or Mixtures of both
Gas flow rate is between 25-35 CFH
Argon, Helium, and Carbon Dioxide are the main three gases used in GMAW

Procedure

Before Welding

Step 1 Safety precaution

Welder ensured the area has a suitable safe work by keep it clean & free of grease, oils &
flammables. In addition, welding bay was closed properly to protect others from any UV
flash exposure. Furthermore, area of welding bench was ensured that it was well ventilated
(with fume extraction). For PPE, long sleeve shirt, long pants, safety shoes, and gauntlet
gloves has to be wore before, during and after weld. The long sleeve shirt is required because
UV rays can cause minor skin burns identical to sun burns. Gauntlet Gloves are required
because they protect your hands from the immense heat created during the welding process.

Step 2 Preparing work piece

Firstly, plate was prepared by cutting it followed by the dimension given. 6mm thickness
plate with 60mm width cut into 150mm length for 2 pieces. Next, by using wire brush and a
piece of remnant fabric, contaminant at the plate such as rust, paint or grease was removed to
ensured good electrical contact during weld.

Step 3 Welding machine setup

For welding machine setup, the equipment of weld was checked to ensure all the cable
connection was fitted tightly and free of fraying or others damage. After that, for electrode
polarity, it was required for (DCEP) direct current electrode positive. Moreover, gas flow was
setup by valve turned into half. (15-20 psi)

Step 4 Work piece setup

After welding machine set up completed, earth clamp was clipped to the working table for
making one completed circuit of electrical flow. And then, by using tack weld mode, 2 pieces
of plate 150mm x 60mm x 6mm was tacked to make fillet (t-joint)

During welding

Step 5 Begin welding

Fillet (T-joint) that has been tacked was positioned to 1F (900 degree work angle). By using 4
step mode, the opposite side of fillet (t-joint) has been used as weld area. Drag (pull)
technique was used during weld the work piece and the gap of contact tip was 6 to 10 mm
from the weld metal. After the first layer finished, the surface of welded area has been
cleaned before it was continued for the second layer.

Welder
Name
Ariff
Fadzil

Specimen
Length
(mm)
150
150

Time During
Weld (sec)

Travel Speed
(mm/min)

Voltage

100
111

90.00
81.08

18.3
20

Heat Input (kJ/sec)

Travel
Current
Speed
133
90.00
100
81.08

Step 6 Surface finishing

Afterward, welded area was cleaned by using wire brush and then spatter has been removed
using chisels.

Heat
Input
1.6226
1.48

Result & Discussion

Mohd Ariff Bin Zakaria (50249113541)

Discussion
Cause

Discontinuities
1.Uneven cap profile

1.excessive weaving/ arc too

2.Overlap

long/short

3.poor welding stop

2.excessive weld
3. improper weld technique

Prevention
1. hand-eye weld technique
required
2. control welding parameter
such as current and speed travel
during weld
3. hand-eye weld technique
required

Welding parameter
Mohd Ariff Zakaria - 50249113541
Material

Mild steel

Work piece size ( L x W x T)

150mm x 60mm x 6mm

Type of joint

Fillet (t joint)

Wire feed diameter size

1mm

Shielding Gas

CO2

Welding current (before weld)

107 ampere

Welding current (during weld)

133 ampere

Voltage (before weld)

18.3 V

Voltage (during weld)

18.2-18.3 V

Mode (2 step/4step)

4 step

Position

1F

Average time taken

1min 40 sec

(travel speed)

(150mm100 sec = 1.5mm/sec)

Heat input

= voltage(V) x current(I) x 60
travel speed(mm/s) x 1000
=18.3 x 133 x 60
1.5(60) x 1000
=1.6226 kJ/mm

Muhammad Fadzil bin Mohd Murad (50249113880)

Discussion
Cause

Discontinuities
1.convexity

1.excessive weaving/ arc too

2.Overlap

long/short

3.poor welding stop

2.excessive weld
3. improper weld technique

Prevention
1. hand-eye weld technique
required
2. control welding parameter
such as current and speed travel
during weld
3. hand-eye weld technique
required

Welding parameter
Muhammad Fadzil bin Mohd Murad - 50249113880
Material

Mild steel

Work piece size ( L x W x T)

150mm x 60mm x 6mm

Type of joint

Fillet (t joint)

Wire feed diameter size

1mm

Shielding Gas

CO2

Welding current (before weld)

100 ampere

Welding current (during weld)

97 ampere

Voltage (before weld)

20 V

Voltage (during weld)

19.8-20.1 V

Mode (2 step/4step)

2 step

Position

1F

Average time taken

1min 51 sec

(travel speed)

(150mm111 sec = 1.35mm/sec)

Heat input

= voltage(V) x current(I) x 60
travel speed(mm/s) x 1000
=20 x 100 x 60
1.35(60) x 1000
=1.48 kJ/mm

Conclusion

For safety precautions in gas metal arc welding, wear PPE during welding progress, it is
mandatory procedure for user to comply the safety basic which is can avoid bad scenario
from happened. Furthermore, by getting familiar with basic equipment/apparatus can also
help user from applying each of the equipment properly during weld. Next, user learnt
how to maintain the machine for example when user had to change the wire electrode
spool from 1.2mm diameter wire electrode to 1.0mm, the roller need to switched to the
other side according to the size of the track of roller. In technical side, user able to know
drag/pull and push gun technique during weld for example when using push/pull
technique, weld bead showed narrower compare to push technique that make wider bead
and less penetration. Moreover, user able to gain skills in fillet (t-joint) weld, such as the
position of metal (1F/2F) weld, the work angle during weld and the distance of wire feed
with weld pool. Meanwhile, user also learnt how to get good metal transfer by control the
current flow. Then, user will get to know advantages, disadvantages & limitations of
Gmaw. For instance, Gmaw can have high travel speeds and deposition rates if it is
compared to Shielded Metal Arc Welding (Stick/SMAW), which can save money on
down time however the welding machine itself is more complex then the SMAW power
supplies, which leads to an increase in equipment costs. In shorts, this this process is one
of the best process that may have great result of weld because it has minimal percentage
for contaminant to get into it.