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MIG MAG Welding Guide For Gas Metal Arc Welding
CONTENTS
I INTRODUCTION 1
II FUNDAMENTALS 1
Principles of Operation 1
Characteristics 2
III TRADITIONAL MODES OF METAL TRANSFER 3
Axial Spray Transfer 3
Globular Transfer 3
Short Circuiting Transfer 3
IV HIGH LEVEL MODES OF METAL TRANSFER 4
Pulsed Spray Transfer (GMAW-P) 4
Surface Tension Transfer 4
V EQUIPMENT 4
Semiautomatic Welding Gun and Accessories 5
Wire Feed Motor 6
Welding Control 6
Shielding Gas Regulators 6
Power Source 6
Power Supply Variables 9
Voltage 9
Slope 9
Inductance 10
Automatic Welding Equipment 11
VI PROCESS REQUIREMENTS AND APPLICATIONS 11
Shielding Gas 11
Inert Shielding Gases, Argon and Helium 12
Mixtures of Argon and Helium 14
Oxygen and CO2 Additions 14
Carbon Dioxide 14
Shielding Gas Selection 14
Electrodes 15
Composition 15
Formulation 15
Selection of Process Variables 15
Equipment Selection 15
Mode of Metal Transfer and Shielding Gas 15
Design and Service Performance 15
Process Control 15
Appearance 15
Electrode Selection 17
Equipment 17
Weld Size 17
Standardization and Inventory 17
Materials Handling System 17
Operating Conditions 17
Deposition Rate 17
Welding Current — Wire Feed Speed 18
Welding Voltage 18
Electrode Stickout 18
Guidelines for Operating Conditions 23
iii
VII PROCEDURES FOR CARBON STEELS 24
Welding Recommendations 24
Wire Feed Speed 24
Arc Voltage 24
Shielding Gas and Gas Mixtures 24
Carbon Dioxide 24
Argon 24
Argon and Carbon Dioxide 24
Preheat & Interpass 25
Horizontal Fillets or Flat Butt Welds by Short Circuiting 26
Vertical Down Fillets or Square Butt Welds by Short Circuiting 26
Vertical Up Welds by Short Circuiting 27
Flat and Horizontal Fillet Welds by Spray Transfer 27
Flat Butt Welds by Spray Transfer 28
Flat and Horizontal Fillet Welds by Pulsed Spray Transfer 28
Vertical Up Fillet Welds by Pulsed Spray Transfer 29
VIII WELDING STAINLESS STEEL 29
Spray Arc Transfer 29
Short Circuiting Transfer 29
Procedure Range Blue Max MIG 30
Flat Butt Welds by Spray Transfer 30
Flat and Horizontal Fillets and Flat Butts by Spray-Arc Transfer 31
Horizontal Flat Fillets or Flat Butt Welds by Short Circuiting 32
Pulsed-Arc Transfer 32
Flat and Horizontal Fillets by Short Circuit Transfer 33
Vertical Up Fillets by Short Circuit Transfer 34
Flat and Horizontal Fillets by Pulsed Spray Transfer 34
IX WELDING ALUMINUM 35
Horizontal Fillets with 5356 Filler Wire 35
Horizontal Fillets with 4043 Filler Wire 36
Flat Butt Welds with 5356 Filler Wire 36
Flat Butt Welds with 4043 Filler Wire 37
Flat and Horizontal Fillet Welds by Pulsed Spray Transfer 37
X SAFE PRACTICES 38
Introduction 38
Handling of Shielding Gas Cylinders & Regulators 38
Cylinder Use 38
Gases 38
Ozone 38
Nitrogen Dioxide 38
Carbon Monoxide 38
Metal Fumes 38
Radiant Energy 39
Noise — Hearing Protection 39
Arc Welding Safety Precautions 40-42
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