MIG Welding Manual

MIG WELDING MANUAL
Department of Industrial and

manufacturing Engineering, UET Lahore
12/17/2013
Table of Contents
SECTION 1 - SAFETY PRECAUTIONS
1-1. Safety Steps
1-2. Important Safety Warning
1-3. Fire
.
..
2
2
2
SECTION 2- GAS METAL ARC WELDING

2-1. Introduction
2-2. Basic equipment for a typical GMAW semiautomatic setup.

2-3. Welding principle
2-4. What else will you need with the welder?
3
3
4
5
SECTION 3- STEPS INVOLVED IN WELDING

3-1. Power Supply and Equipment
3-2. preparing the wire
3-3. Feeding the wire to the torch

3-4. Setting the roller tension
3-5. setting the reel tension
3-6. Wire speed reference
3-7. Preparing the metal
3-8. Holding the torch
3-9. Positioning the tip
3-10. Welder movement
3-11. Welding direction
3-12. Applications of MIG Welding
3-13. What metals can GMAW weld?
3-14. MIG Advantages/Disadvantages
3-15. Steps for good welding
..
...
11
11
12
13
13
14
15
15
15
16
16
18
18
19
SECTION 4- TROUBLESHOOTING GUIDE

4-1. Excessive spatter
4-2. Porosity
4-3. Incomplete fusion
4-4. Excessive penetration
4-5. Lack of penetration
4-6.burn through
4-7.waviness of bead
4-8. Distortion
..
1 Department of Industrial & Manufacturing Engineering,

University of Engineering & Technology, Lahore
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Prepared For: Sir Javed Anwar

Prepared By: 07-IME-01,47,49
Improved By: 11-IME-47,49,30,31,40
1-1. Safety Steps:

The light that is generated by any form of arc welding is extremely bright. It will burn
your eyes and your skin just like the sun will if you don't protect yourself. The first
thing you will need to weld is a welding mask. An auto-darkening welding mask is really
helpful if you are going to do a bunch of welding. Manual masks require you to jerk your
head dropping the mask into position or require using a free hand to pull the mask down.
This allows you to use both your hands to weld, and not worry about the mask. The light
has a tendency to draw on lookers who might need to shielded from being burned too.
Wear gloves and leathers to protect yourself from molten metal splattering off of your
work piece. Some people like thin gloves for welding so you can have a lot of control. In
TIG welding this is especially true, however for MIG welding you can wear whatever
gloves you feel comfortable with. The leathers will not only protect your skin from the
heat produced by welding but they will also protect your skin from the UV light produced
by welding.
Make sure that you are wearing clothing made from leather or cotton. Plastic fibers like
polyester and rayon will melt when they come into contact with molten metal and will
burn you. Cotton will get a hole in it, but at least it won't burn and make hot metal goop.
Do not wear open toed shoes or synthetic shoes that have mesh over the top of your
toes. Hot metal often falls straight down.
Weld in a well-ventilated area. Welding produces hazardous fumes which you shouldn't
breathe in if you can avoid it. Wear either a mask or a respirator if you are going to be
welding for a prolonged amount of time.
1-2. Important Safety Warning:

DO NOT WELD GALVANIZED STEEL. Galvanized steel contains a zinc coating that
produces carcinogenic and poisonous gas when it is burned. Exposure to the stuff can result in
heavy metal poisoning (welding shivers) - flu like symptoms that can persist for a few days, but
that can also Cause permanent damage.
1-3. Fire:
Molten metal can spit several feet from a weld. Grinding sparks are even worse. Any sawdust,
paper or plastic bags in the area can smolder and catch fire, so keep a tidy area for welding. Your
attention will be focused on welding and it can be hard to see what's going on around you if
something catches fire. Reduce the chance of that happening by clearing away all flammable
objects from your weld area. Keep a fire extinguisher in your workshop.


Improved By: 11-IME-47,49,30,31,40
SECTION 2- GAS METAL ARC WELDING

2-1. Introduction:
Gas Metal Arc Welding (GMAW) is a welding process which joins metals by heating the
metals to their melting point with an electric arc. The arc is between a continuous,
consumable electrode wire and the metal being welded. The arc is shielded from
contaminants in the atmosphere by a shielding gas.
MIG Welding Names:

MIG welding, or MIG, is an acronym for Metal Inert Gas welding. MIG is a commonly
used and accepted slang term that was appropriate when the process was first invented. In the
beginning, the gasses used for shielding the weld area were known as Inert or Nobel
gasses. Today the proper terminology is Gas Metal Arc Welding or GMAW. This is a
better description of this welding process because most gasses or gas mixtures used are neither
Inert nor Nobel gasses, and in many cases they are actually reactive gasses. Some people also
refer to this process as Wire Wheel Welding because it uses a wire wheel to feed the filler
metal to the weld joint. In the end, MIG welding is still the most popular term. However, when
searching for information or jobs in the welding field, the term GMAW or Gas Metal Arc
Welding is the correct one.
2-2. Basic equipment for a typical GMAW semiautomatic setup:


Improved By: 11-IME-47,49,30,31,40
2-3. Welding principle:

MIG welding uses an arc of electricity to create a short circuit between a continuously fed anode
(+ the wire-fed welding torch) and a cathode ( - the metal being welded) The heat produced by
the short circuit, along with a non-reactive (hence inert) gas locally melts the metal and allows
them to mix together. Once the heat is removed, the metal begins to cool and solidify, and forms
a new piece of fused metal.
Gas metal arc welding (GMAW or MIG welding) is an electric arc welding process that uses a
spool of continuously fed wire. It can be used to join long stretches of metal without stopping.
The welder, or apparatus, holds the wire feeder and a wire electrode is fed into a weld at a
controlled rate of speed, while a blanket of inert argon gas shields the weld zone from
atmospheric contamination. Shielding the arc and molten weld pool is done by "externally"
supplying gas or a gas mixture.
There are three components to MIG welding:
1. Electricity needed to produce heat
2. Electrode needed to fill the joint
3. Shielding gas needed to protect the weld from air
GMAW can be done in three different ways:

Semiautomatic Welding:
Equipment controls only the electrode wire feeding. Movement of welding gun is
controlled by hand. This may be called hand-held welding.
Machine Welding:
Uses a gun that is connected to a manipulator of some kind (not hand- held). An
operator has to constantly set and adjust controls that move the manipulator.
Automatic Welding:
Uses equipment which welds without the constant adjusting of controls by a
welder or operator.


Improved By: 11-IME-47,49,30,31,40
2-4. What else will you need with the welder?

Torch:
The torch almost always comes with the welder, but there are differences to consider.
Torches can wear and depending on how much use the welder gets they may need to be
replaced during the life of the welder.
Gas Regulator:
The main choice in gas regulator for a full sized bottle is whether to go for the cheaper
single gauge one (that measures the pressure remaining in the bottle) or the twin gauge
(which also measures flow rate).
Safety Equipment:
Molten metal is hot, and the UV light produced by welding is a lot stronger and nastier
than sunlight. Cotton overalls and welding gauntlets (thick heat resistant gloves) are a
must.
Welding Mask:
Most hobby welders come with a hand held mask which is useless as the spare hand can
be put to far better use in steadying the welding torch.
Shielding Gases:
Argon and helium are the two inert shielding gases used for protecting the molten weld
pool. The inert classification indicates that neither argon nor helium will react chemically
with the molten weld pool.
Assuming you are using a shielding gas with your MIG welder there will be a cylinder of
gas behind the MIG. This is either 100% Argon or a mixture of CO2 and Argon. This gas
shields the weld as it forms. Without the gas your welds will look brown, splattered and
just generally not very nice
IF WE DO NOT USE SHIELDING???

Most metals exhibit a strong tendency to combine with oxygen (to form oxides) and to a
lesser extent with nitrogen (to form metal nitrides). Oxygen will also react with carbon to
form carbon monoxide gas. These reaction products are all a source of weld deficiencies
in the form of: fusion defects due to oxides; loss of strength due to porosity, oxides and
nitrides; and weld metal embrittlement due to dissolved oxides and nitrides. These
reaction products are easily formed since the atmosphere is more or less composed of 80
percent nitrogen and 20 percent oxygen. The primary function of the shielding gas is to
exclude the surrounding atmosphere from contact with the molten weld metal.


Improved By: 11-IME-47,49,30,31,40
Shielding Gases for MIG Welding of Aluminum:

Argon allows a calm and stable metal transfer, but in the case of penetration intensity and
security against porosity due to hydrogen it is not as resistant as argon-helium mixtures. Helium
is not appropriate because of very uneven coarse drops and metal transfer carried by the
background current. Helium-argon mixtures with between 30 % and 70 % helium are proven.
The mixture most used is 50% argon and 50% helium.


Improved By: 11-IME-47,49,30,31,40
CO2 vs. Argon/CO2 MIX:

The weld to the right was made using So% Argon, 20%
C02 shielding gas. It was nice and easy to do. The arc
was very stable and controllable and the weld turned out
quite neat.10o% C02 gas was used for the weld on the
left. The arc felt much less stable with C02 shielding gas,
and the weld progressed in a stuttering fashion with
blobs of molten weld (spatter) being blown off at regular
intervals. That's a bit of spatter stuck to the weld about half way up
on the left. The arc also seemed slightly
brighter than with the argon mix. Carbon dioxide is less
expensive than argon gas.

Improved By: 11-IME-47,49,30,31,40
Pure Argon Gas:

Pure Argon is intended for aluminum welding rather
than for steel. The arc was slightly less even than the
Argon/C02 mixes, and tended to stray. It was tricky to
control exactly where the arc struck the steel especially
on thin metal. The weld build up was much higher than
with any of the other shielding gasses (bad), and there
was an odd roughness around the edge of the weld
possibly due to stray arcing.
Argon/CO2 Mix vs. Argon shield:

Argo shield Light is approximately 93% Argon, 5% C02
and 2% oxygen. The oxygen in Argo shield is supposed to
improve wetting and make the weld smoother, and
indeed the weld made using Argo shield is very slightly
smoother than the other weld. The two gases should
come out much the same as they are equivalent gases,
both designed for thin metal welding. The 2% oxygen in
Argo shield (tri-mix) has a similar effect to adding 15%
C02 to pure Argon.
Note:
The choice of a shielding gas depends on several
factors, most importantly the type of material
being welded and the process variation being
used. Pure inert gases such as argon and helium
are only used for nonferrous welding; with steel
they do not provide adequate weld penetration
(argon) or cause an erratic arc and encourage
spatter (with helium). Pure carbon dioxide, on the
other hand, allows for deep penetration welds but
encourages oxide formation, which adversely
affect the mechanical properties of the weld. Its
low cost makes it an attractive choice.


Improved By: 11-IME-47,49,30,31,40
3-1. Power supply & equipment:

The power supply and equipment are what make this type of welding process possible. Once you
understand the type of equipment used then the inner workings become simple.
MIG welding power supplies are referred to as CV or Constant Voltage power supplies.
What this power supply does is produce electrical current to create an arc to weld the metal
with. The term CV means that the heat settings are controlled with voltage. When MIG welding,
the machine is always set by voltage and
this type of power supply keeps the voltage at a consistent level. What happens is that the
amperage fluctuates, but the voltage stays in the range that it is set
When comparing MIG welding to Arc or TIG welding, MIG welding machines use voltage
settings to set the machine. TIG and Arc welding machines use amperage to set the machine or a
constant amperage power supply
MIG welders have three main settings:

1. Arc force
2. Voltage Setting
3. Wire Feed Speed.
1-Arc force knob

This controls the penetration of the weld via a control knob on machine (On older
machines this was known as choke, you may have 2-3 connectors for the earth cable)
Low setting = Less penetration and low splatter, used for thinner materials. This really
helps when welding car bodywork!
High setting = High penetrate and more splatter (harsher weld) used for thicker materials
2-Wire speed knob:

Wire speed depends on thickness of metal to be welded. We should have to increase the wire
speed through knob when there are splatters are producing by welding. Splatters can be produced
either increase or decrease the wire speed. We check the splatters by manual working and adjust
the wire speed knob according it.
3-Voltage knob:
Voltage should be increase with wire speed & wire speed depends on metal to be welded.
Voltage should be increase or decrease according to the wire speed knob.


Improved By: 11-IME-47,49,30,31,40
Wire Speed
Knob
Voltage Knob
Arc Force
Knob
Trigger Controller
Mode
Wire Thickness
Switch
Wire & Gas

Checking Switch
Wire Thickness Switch:
Wire thickness switch is adjusted according to the electrode thickness.

Wire & Gas Checking Switch
When we push the button to Gas/Preheat position it indicate that either gas is coming or not by
light signal. When we push the button to wire position it indicates either wire is coming or not.
When we adjust the button to center. It means welder is in working position.
Trigger Controller Mode:

Machine is automatic as well manual operating.
2T means manual working. Push the trigger and carry out welding by pressing it. Release
your hand when welding complete.
4T means automatic working. Push the trigger and release hand from trigger and carry
out welding. In the end push trigger again when welding completed.


Improved By: 11-IME-47,49,30,31,40
3-2. preparing the wire:

The wire reel mounting includes a spring tensioner. This
tensioner should be initially tightened to the point where
the reel of wire doesn't unravel under its own spring
tension. The first 3 inches of wire should be as straight
as possible to reduce the chance of damage to the liner or
snagging as the wire is fed through. Sharp wire cutters
can be used for trimming. Letting go of the end of the
wire would cause it to unravel and tangle.
3-3. Feeding the wire to the torch:

The wire is inserted through the guide tube and over the
roller. On the torch side of the welder the small hole of
the end of the wire liner should be visible. The end of the
wire can be aligned with that hole using a small
screwdriver or the piece of wire that was removed
at the start. The wire can then be pushed into the liner
manually for a few inches, and should feed easily and
without any force. If force is required it is likely that the
wire has missed the liner.
The wire feed roller itself will normally have two grooves,
and is secured either by a grub screw in the side of the
roller, or a knurled plastic cap as in the photo.
Rust or grease on the wire can reduce the effectiveness of
the rollers, and they need to be cleaned with a dry cloth
before inserting the wire.
With the wire pushed a couple of inches into the liner
replace the tensioner clamp, switch on the welder and use
the wire feed mechanism to push the wire through the liner.
On some welders it can help to remove the contact tip from
the end of the torch before feeding the wire through. The
gas shroud is secured by a spring and can be removed by
pulling and twisting in a clockwise direction, and the tip has
a standard screw thread that unscrews in an anti-clockwise
direction (viewed as in the photo). Never unscrew the tip
when it is still hot or it may break or strip the thread inside
the torch.


Improved By: 11-IME-47,49,30,31,40
3-4. Setting the roller tension:

The wire is driven by friction between the wire feed drive
roller and the wire. This method of drive commonly causes
problems on hobby welders where the tensioner is not
robust. Care in tensioning the wire feed can prolong the
life
of the tensioner mechanism. Tightening the tensioner fully
can cause the tensioners or tensioner mountings to bend
and could also shear the motor gearing if the wire were to
stick in the tip during welding.
One way to judge the wire feed tension is to grip the
wire very lightly between your fingers and pull the trigger.
Care is needed with this approach as if the wire were to
touch the earth clamp it would arc, resulting in burned
fingers And possibly arc eye. Starting with very little
tension on the wire feed mechanism, Increase the tension
until the wire feed stops slipping, but do not grip the
wire so tightly that the wire feed motor slows.
The wire should ideally start to slip inside the rollers before
the motor stalls.


Improved By: 11-IME-47,49,30,31,40
3-5. setting the reel tension:

Finally check the tension on the wire reel. The tensioner
on the reel is there to stop the wire becoming loose and
tangled, but the tension should be as light as possible to
make life easy for the wire feed mechanism. Set your
wire speed to the maximum you are likely to use, and
press the trigger on the torch. The wire reel should stop
without unraveling when you lift off the trigger.
Avoiding wire feed problem:

Wire feed problems are commonly caused by rusty
welding wire. The rust acts as a lubricant on the feed
rollers causing slip, and as an abrasive on the wire liner
which increases resistance.
Wire can quickly go rusty when left unused inside a
welder. Ideally the wire should be removed and stored
indoors when the welder is not in use. This wire in the
photo was reusable after the top couple of layers of wire
had been removed ..
3-6. Wire speed reference:

The o.6mm wire size figures have been tested to 2mm and the figures are extrapolated.
The o.8mm figures have been extrapolated from the o.6mm results so will be less reliable,
but they are at least a starting point. Where the figures are against a grey background the
wire size isn't really suitable for the material thickness. The markings on welder wire feed
controls do not represent speed in meters per minute. Measure the speed using a
stopwatch and tape measure. It might be useful to mark positions around the wire feed
knob for future use.


Improved By: 11-IME-47,49,30,31,40
3-7.Preparing the metal:

Metal needs to be completely clean and free from rust or
paint before welding. Not just because it is difficult to arc
against a dirty surface, but because any contaminants will
tend to find their way into the weld and reduce its strength.
An area should be cleaned for the earth clamp mounting
too. Light use of an angle grinder or flap wheel will
quickly
remove surface rust and paint, and for more inaccessible
areas an air grinder can be effective.


Improved By: 11-IME-47,49,30,31,40
3-8. Holding the torch:

MIG can be used one handed, but it's much easier when you
can use both hands to steady the torch. Throw away the
hand held mask that came with the welder and buy a full
face mask. Welding control will be further improved if you
can rest an arm against something solid. In the photo the
left arm is resting on the chassis and supporting the neck of
the torch. The back of the fingers are too close to the weld
will get hot quickly, but this position should be fine for a
short period of welding.
The head is angled to one side to make the weld pool visible
(the gas shroud gets in the way).
3-9. Positioning the Tip:

Tend to angle the torch at maybe 20 degrees from vertical
with the shroud angled forward.
The contact tip should be about 6mm to 10mm from the
metal to be welded, so cutting the wire about 10mm long
and holding the torch so the wire touches the sheet is a
good way to position a MIG welder.
3-10. welder movement:

There are a variety of torch movements used in MIG
welding. Generally some form of zigzag or weaving motion
is used to ensure the arc acts against both sheets to be
welded.
For thinner metal preferred curve is a zigzag as illustrated in
the photo.


Improved By: 11-IME-47,49,30,31,40
3-11. welding direction:

This describes welding in the "push" direction. Pushing the
torch rather than pulling is a good habit to get into as it
improves coverage of shielding gas.
For thin mild steel welded horizontally the direction of
welding doesn't make a great deal of difference to the weld,
so if visibility is better with the pull technique then that can
be used.
3-12. Applications of MIG Welding:

Garage
Body shops
Maintenance
Repair
Fabrication
Manufacturing
More Applications are:

Chesis of Bike
MIG welding is also used in fuel tank of Honda-125


Improved By: 11-IME-47,49,30,31,40


Improved By: 11-IME-47,49,30,31,40
3-13. What metals can GMAW weld?

1. Aluminum
2. Carbon steel
3 Copper
4 Low Alloy Steels
S Magnesium
6. Nickel
7 Stainless Steel
8. Titanium
3-14. MIG Advantages:

High productivity, because you don't have to stop to change rods or chip and
brush the weld frequently.
Easy to learn and makes great-looking welds.
Almost no cleanup.
Can weld on stainless, mild steel, and aluminum.
Can weld in all positions.
A minimum of weld splatter
Requires less operator skill than TIG welding
Allows long welds to be made without starts or stops
Metals as thin as o.5842mm may be weld.
MIG Disadvantages:
Can't check watch, count money, smoke cigarette, or talk to buddy as often.
Requires a cumbersome bottle of shielding gas.
Costs money for consumables, such as tips and nozzles.
Isn't worth on paint, rust, or dirty surfaces.
Not good for thick steel, because it doesn't get the proper penetration
The use of an inert gas makes this type of welding less portable than arc welding which
requires no external source of shielding gas
Produces a somewhat sloppier and less controlled weld as compared to TIG
(Tungsten Inert Gas Welding)
GMAW is more difficult to use in tight corners as the gun is somewhat large and the gun cable
is stiff and inflexible.


Improved By: 11-IME-47,49,30,31,40
3-15. Steps for good welding:

Keep a 1/4 to 3/8 in stick out (electrode extending from the tip of the contact tube.) (Refer
to Diagram 1.)
For thin metals, use a smaller diameter wire. For thicker metal use a larger wire and a
larger machine.
Use the correct wire type for the base metal being welded. Use stainless steel wires for
stainless steel, aluminum wires for aluminum, and steel wires for steel.
Use the proper shielding gas. C02 is good for penetrating welds on steel, but may be too
hot for thin metal. Use 75% Argon/25% C02 for thinner steels. Use only Argon for
aluminum. You can use atriple-mix for stainless steels (Helium + Argon + C02).
For best control of your weld bead, keep the wire directed at the leading edge of the weld
pool.
When welding out of position (vertical, horizontal, or overhead welding), keep the weld
pool small for best weld bead control, and use the smallest wire diameter size you can.
Be sure to match your contact tube, gun liner, and drive rolls to the wire size you are
using.
Clean the gun liner and drive rolls occasionally, and keep the gun nozzle clean of spatter.
Replace the contact tip if blocked or feeding poorly.
Keep the gun straight as possible when welding, to avoid poor wire feeding.
Use both hands to steady the gun when you weld. Do this whenever possible.
Keep wire feeder hub tension and drive roll pressure just tight enough to feed wire, but
don't over tighten.
Keep wire in a clean, dry place when not welding, to avoid picking up contaminants
that lead to poor welds.
A drag or pull gun technique will give you a bit more penetration and a narrower bead.
A push gun technique will give you a bit less penetration, and a wider bead. (Refer to
Diagram3.)


Improved By: 11-IME-47,49,30,31,40


Improved By: 11-IME-47,49,30,31,40
4-1. Excessive spatter:
Excessive Spatter - scattering of

molten metal particles that cool to solid
form near weld bead
Possible Causes
Wire feed speed too high.
Voltage too high..
Electrode extension (sickout)
too long.
Work piece dirty.
Insufficient shielding gas a:t
welding arc..
Dirty welding wire
Corrective Actions
Select lower wire feed speed.
Select lower voltage range .
Use shorter electrode extension {stick out) .
Remove all grease, oil, moisture . rust. paint. undercoating. and dirt from work
surface before welding.
! Increase flow of shielding gas at regulator/flow meter and /or prevent drafts near
welding arc
Use clean. Dry welding wire.
Eliminate pickup of o:il or lubricant on welding w ire from feeder or liner.
4-2. Porosity:
Porosity - small cavities or holes
resulting from gas pocket in
weld metal
Possible Causes
Corrective Actions
Wrong gas_
Dirty welding
wire.
Use welding grade shielding gas; changed to different gas_
Work piece dirty.
Use clean , dry welding wire.

Remove all grease, oil, moisture, :rust, paint, coatings, and dirt from work
surface before welding_


Improved By: 11-IME-47,49,30,31,40
4-3. Incomplete fusion:
Incomplete e Fusion - failure of

weld metal to fuse completely with
base metal or a preceding weld
bead.
Possible Causes
Work piece dirty.
Insufficient heat
input
Improper welding
Technique.
Corrective Actions
Remove all grease, oil, moisture, rust, paint , coatings, and dit1 from work
surface before welding.
Select higher voltage range and/or wire feed speed .
Place stringer bead in proper location(s) at joint during welding
4-4. Excessive penetration:
Excessive Penetration
Good Penetration
Excessive Penetration - weld metal

melting through base metal and
hanging underneath weld.
Possible Causes
Corrective Actions
Excessive heat input.
Select lower voltage range and reduce- wire feed speed.

Increase travel speed.


Improved By: 11-IME-47,49,30,31,40
4-5. Lack of penetration:
Lack of Penetration
Good Penetration
Lack Of Penetration - shallow

fusion between weld metal and
base metal.
Possible Causes
Improper join t
preparation.
Improper weld
technique.
Insufficient heat
input.
Corrective Actions
Material too thick . Joint preparation and design must provide access to
bottom of groove while
maintain pro per weld ding wire extension and arc characteristics.
Maintain normal gun angle of 0 to 15 degrees to achieve maximum
penetration.
Se elect higher wire feed speed and/or select higher voltage range..
4-6. Burn through:

Burn through- weld metal
melting completely through base
metal resulting in holes where
no metals remain
Possible Causes
Corrective Actions
Select lower voltage range and reduce wire feed speed


Improved By: 11-IME-47,49,30,31,40
4-7. Waviness of bead:
Waviness Of Bead - weld metal that

is not parallel and does not cover
the joint formed by base metal.
Possible Causes
Corrective Actions
Welding wim extends too

far out of
nozzle.
Be sure welding wire extends not more than 1/2 in (13 mm) beyond
nozzle.
Unsteady hand.
Support hand on solid surface or use two hands.
4-8. Distortion:
Distortion n - contrac1Jion of weld

metal doming welding that forces
base metal to move.
Possible Causes
Corrective Actions
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower voltage range and/or reduce wire feed speed.

Increase travel speed.
Weld in small segments and allow cooling between welds.


Improved By: 11-IME-47,49,30,31,40
H.M.Siddique
2011-IME-47
Imran Liaqat
2011-IME-49
Muhammad Ahmad
2011-IME-31
Jazib Shahkil
2011-IME-30
Muhammad Awais
2011-IME-40
Date: 17-12-2013


Improved By: 11-IME-47,49,30,31,40

MIG Welding Manual

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MIG WELDING MANUAL

Department of Industrial and

SECTION 2- GAS METAL ARC WELDING

2-2. Basic equipment for a typical GMAW semiautomatic setup.

2-4. What else will you need with the welder?

SECTION 3- STEPS INVOLVED IN WELDING

3-3. Feeding the wire to the torch

SECTION 4- TROUBLESHOOTING GUIDE

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1-1. Safety Steps:

1-2. Important Safety Warning:

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SECTION 2- GAS METAL ARC WELDING

MIG Welding Names:

2-2. Basic equipment for a typical GMAW semiautomatic setup:

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2-3. Welding principle:

GMAW can be done in three different ways:

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2-4. What else will you need with the welder?

IF WE DO NOT USE SHIELDING???

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Shielding Gases for MIG Welding of Aluminum:

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CO2 vs. Argon/CO2 MIX:

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Pure Argon Gas:

Argon/CO2 Mix vs. Argon shield:

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3-1. Power supply & equipment:

MIG welders have three main settings:

1-Arc force knob

2-Wire speed knob:

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Wire & Gas

Wire Thickness Switch:

Wire thickness switch is adjusted according to the electrode thickness.

Trigger Controller Mode:

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3-2. preparing the wire:

3-3. Feeding the wire to the torch:

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3-4. Setting the roller tension:

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3-5. setting the reel tension:

Avoiding wire feed problem:

3-6. Wire speed reference:

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3-7.Preparing the metal:

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3-8. Holding the torch: