Wednesday, 7 March 2012

MIG Filler Wire

Low carbon or mild steel filler wire specifications are found in the CSA standard W48.8 and in the AWS standard A5.18.

CSA
ER 480S-6
E = Electrode
R = The wire can be used as filler rod for TIG welding
480 = 480 MPa tensile strength
S = Solid wire
6 = Deoxidizers and other additions in the wire


AWS
ER 70S-6

E = Electrode
R = The wire can be used as filler rod for TIG welding
70 = 70,000 psi tensile strength
S = Solid wire
6 = Deoxidizers and other additions in the wire






MIG Gases

MIG Gases (Short Circuit Transfer)
Metal Gas Advantages
Carbon Steel 75% argon + 25% carbon dioxide Less than 1/8” thick
-High welding speed
-No burn-through
-Minimum distortion and spatter
75% argon + 25% carbon dioxide More than 1/8” thick
-Minimum spatter
-Clean weld appearance
-Good puddle control in vertical and overhead positions
-Both GMAW and FCAW
carbon dioxide -Deeper penetration
-Faster welding speeds
-Both GMAW and FCAW
Stainless Steel 90% helium + 7.5% argon + 2.5% carbon dioxide -No effect on corrosion resistance
-Small heat-affected zone
-No undercut
-Minimum distortion
Low Alloy Steel 60-70% helium + 25-35% argon + 4-5% carbon dioxide -Minimum reactivity
-Excellent toughness
-Excellent arc stability, wetting characteristics and bead contour
-Little spatter.
75% argon + 25% carbon dioxide -Fair toughness
-Excellent arc stability, wetting characteristics and bead contour
-Little spatter
Aluminum, Copper, Magnesium, Nickel and their alloys Argon & argon + helium -Satisfactory on sheet metal
-Argon-helium preferred on material over 1/8”


MIG Gases (Spray Transfer)
Metal Gas Advantages
Carbon Steel Argon + 1-5% oxygen -Improved arc stability
-More fluid and controllable weld puddle
-Good bead contour
-Minimum undercut
-Higher speeds than pure argon
Argon + 3-10% carbon dioxide -Good bead shape
-Minimum spatter
-Reduced chance of cold lap
-Flat/horizontal position only
Low Alloy Steel Argon + 2% oxygen -Minimum undercut
-Good toughness
Aluminum Argon Up to 1" thick
-Best metal transfer and arc stability
-Least spatter
35% argon + 65% helium Up to 1" thick
-Higher heat input than pure argon
-Improved fusion characteristics with 5XXX series Al-Mg alloys
25% argon + 75% helium Over 3” thick
-Highest heat input
-Minimum porosity
Magnesium Argon -Excellent cleaning action
Stainless Steel Argon + 1% oxygen -Improved arc stability
-More fluid and controllable weld puddle
-Good bead contour
-Minimum undercut on heavier stainless steels
Argon + 2% oxygen -Better arc stability & welding speed than 1% oxygen mixture for thinner stainless steels
Copper, nickel and their alloys Argon -Good wetting characteristics
-Decreased fluidity of weld metal for thickness' up to 1/8”
Argon + helium -Higher heat inputs to 50 and 75% helium mixtures offset high heat dissipation of heavier gauge materials
Titanium Argon -Good arc stability
-Minimum weld contamination
-Inert gas backing is required to prevent air contamination on back of weld















Mig Whip Size


Whip Size
Amps Max. Cable Length Cable Size
200 15' No. 1
300 15' No. 2/0
400 15' No. 3/0
500 15' No. 4/0
600 15' No. 2-2/0

Tuesday, 6 March 2012

MIG

MIG welding (also known as GMAW or wire welding) is one of the most popular forms of welding. It is mainly used in high production projects where speed is a factor.

  • MIG = Metal Inert Gas
  • GMAW = Gas Metal Arc Welding
  • Always DC current. DCEP usually for steel and always for aluminum.
  • Often constant potential (CP/CV) machines used.
  • High deposition rate
  • 92% - 98% filler metal forms weld deposit. 
  • Concentrates more current at one point than SMAW arc, producing deeper penetration.
  • Less heat input per linear inch of weld.
  • Suited to welding low carbon structural steels, low alloy stainless steels and hardsurfacing.
  • Penetration is highest when doing globular transfer.
  • Spray transfer requires a minimum of 80% argon and only on DCEP. 
  • Longer stickout = voltage increases/current decreases 
  • Shorter stickout = voltage decreases/current increases
  • Inductance controls the rate of current rise. 
  •  


Metal Melting Temperatures

 Metal Melting Point
(Celcius) (Farenheit)
Admiralty Brass 900 - 940 1650 - 1720
Aluminum 660 1220
Aluminum Bronze 600 - 655 1190 - 1215
Antimony 630 1170
Beryllium 1285 2345
Beryllium Copper 865 - 955 1587 - 1750
Bismuth 271.4 520.5
Brass 930 1710
Cadmium 321 610
Cast Iron, gray 1175 - 1290 2150 - 2360
Chromium 1860 3380
Cobalt 1495 2723
Copper 1084 1983
Cupronickel 1170 - 1240 2140 - 2260
Gold 1063 1945
Hastelloy C 1320 - 1350 2410 - 2460
Inconel 1390 - 1425 2540 - 2600
Incoloy 1390 - 1425 2540 - 2600
Iridium 2450 4440
Iron 1536 2797
Lead 327.5 621
Magnesium 650 1200
Manganese 1244 2271
Manganese bronze 865 - 890 1590 - 1630
Mercury -38.86 -37.95
Molybdenum 2620 4750
Monel 1300 - 1350 2370 - 2460
Nickel 1453 2647
Niobium (Columbium) 2470 4473
Osmium 3025 5477
Platinum 1770 3220
Plutonium 640 1180
Potassium 63.3 146
Red Brass 990 - 1025 1810 - 1880
Rhodium 1965 3569
Selenium 217 423
Silicon 1411 2572
Silver 961 1760
Sodium 97.83 208
Carbon Steel 1425 - 1540 2600 - 2800
Stainless Steel 1510 2750
Tantalum 2980 5400
Thorium 1750 3180
Tin 232 449.4
Titanium 1670 3040
Tungsten 3400 6150
Uranium 1132 2070
Vanadium 1900 3450
Yellow Brass 905 - 932 1660 - 1710
Zinc 419.5 787
Zirconium 1854 3369




























































































































































MIG like TIG

Everyone wants to make their welds look like TIG welds these days. To do so you don't really have to do much. If you just step forward, then pause and let your puddle fill in you will get the general profile of a TIG weld. Just practice with your rate of travel and pause length and you will have it in no time.
This is my attempt:

TIG

TIG welding may be one of the more difficult welding processes to learn but once you get it down it just looks and feels like you should have been doing it all along.

Here's some tips to get you started:



  • TIG = Tungsten Inert Gas
  • GTAW = Gas Tungsten Arc Welding
  • Tungsten Melting Temp.=3375ºC (6100ºF)
  • Water cooled torch for amperage’s over 150 A
  • TIG machines must produce a constant current (CC) 
  • Mild and stainless steel = DCEN (approx. 2/3rds of heat in workpiece, 1/3rd of heat in electrode)
  • Aluminum = AC or ACHF (Greater current during the DCEN half cycle and a reduced DCEP half cycle)
  • Water Cooling Pressure = Around 35 psi (245 kPa), approx. 1L per minute.
  • Pulsed Current used for thinner materials and for vertical and overhead positions.