How to Mig Weld: MIG WELDING OR flUX CORE: ARTICLE FROM INSTRUCTABLES PM ON MIG WELDING MIG welding was developed in the 1940's and 60 years later the general principle is st...


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Mig Welding from webmetalnews

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web metal news article 2/2011
Power Supply and 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.

MIG welding requires a wire feed system. The wire feed system is what feeds the electrode, or filler wire, to the weld joint. This is where the term “Wire Wheel Welding” comes from. The wire feeds come in many different forms. Some are part of the power supply, and the higher-end models come in stand-alone form or are contained inside a briefcase. The wire feed is regulated in IPM or “Inches per Minute”. This is how the speed of the filler wire is regulated and set. The wire feed system also controls shielding gas and all welding operations that are signaled from the MIG gun.
Finally there is the MIG gun. The MIG gun has a handle with a trigger that is attached to the wire feed through a cable. The MIG gun feeds the filler wire, the shielding gas, and electricity to the joint. Once the welder hits the trigger, the MIG gun shields the weld area from the air, produces the Arc, and starts the welding process by feeding wire to the joint.

Shielding Gases

Shielding gas is what makes the MIG welding process possible. There are many types of shielding gasses used for MIG welding. Since the electrodes are a solid metal wire they always need some form of shielding from the air. The gasses range from inert gases to reactive ones. In many cases, the gasses used are a combination of two or more gasses. Some of the commonly used gasses are:
  • Argon
  • Carbon Dioxide
  • Helium (in rare cases)
  • Oxygen (in small percentages)
For most welding applications a combination of Argon and Carbon Dioxide gasses are used. When it comes to the welding gasses, Argon produces a cleaner weld and the Carbon Dioxide helps the weld penetrate deeper. Carbon Dioxide can be used alone for thinner metals, but it also produces a lot of smoke while welding. Some of the most commonly used gasses for welding mild steel are:
  • 100% Carbon Dioxide
  • 25% Carbon Dioxide and 75% Argon
  • 2% Carbon Dioxide and 98% Argon
The mixtures are referred to as C25 and C2. The C stands for Carbon Dioxide and the number is the percentage of Carbon Dioxide in the mixture. It is assumed that the rest of the gas in the mixture is Argon. Argon by itself is used for welding:
  • Aluminum
  • Copper
  • Nickel
  • Titanium

How to Mig

Mig Welding

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Here is more information on Mig welding from metalwebnews
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.

Weldability of Metals

MIG can weld almost any metal. One of the biggest attractions about the MIG process is how fast it is able to weld more than just steel.  The metals that are most commonly welded are:
  1. Mild Steel
  2. Stainless Steel
  3. Aluminum
This process can weld many more alloys and combination of metals. One example is welding dissimilar metals such as stainless steel to steel. Other metals that can be welded range from copper to titanium. The list of metals that can be welded is extensive and range from very common metals to the extremely exotic.


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Flux Core Welding with Feed and Mig Welders

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Flux Core Welding is so much fun you will love it.  If you already know how to weld this site will give you some tips and instruction that may help you improve your technique.  I hope you find it useful and that your enthusiasm for Flux Core Welding will be much greater after visiting this site. 

I learned how to weld with a stick welder but soon after I found out about Flux Core Welding with wire feed and Mig welders.  After trying the feed welder a couple of times I was hooked.  The great thing about a flux core welder is that it is so easy to use.  You can get a welder that plugs into your standard 120 outlet and most Mig welders can be used without inert gas when using flux cored wire. 

You can also get a feed welder that will only weld using flux core wire.  These feed welders will not allow Mig welding but they are priced well and they can do just about anything. 

Flux Core Welding does not produce perfect weld beads much of the time and a certain amount of grinding or sanding of FCW welds can be expected if you need ultra smooth surfaces.  However, for tack welding or welds that will not be visible, the flux core feed welder is awesome.