Section 13

MIG/MAG Welding

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MIG/MAG Welding
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13

MIG/MAG Welding

13.1

Process
Known in the US as gas metal arc welding (GMAW), the MIG/MAG welding
process (Figure 13.1) is a versatile technique suitable for both thin sheet
and thick section components in most metallic materials. An arc is struck
between the end of a wire electrode and the workpiece, melting both to form
a weld pool. The wire serves as the source of heat (via the arc at the wire
tip) and filler metal for the joint and is fed through a copper contact tube
(also called a contact tip) which conducts welding current into the wire. The
weld pool is protected from the surrounding atmosphere by a shielding gas
fed through a nozzle surrounding the wire. Shielding gas selection depends
on the material being welded and the application. The wire is fed from a reel
by a motor drive and the welder or machine moves the welding gun or torch
along the joint line. The process offers high productivity and is economical
because the consumable wire is continuously fed.

Figure 13.1 MIG/MAG welding.

The MIG/MAG process uses semi-automatic, mechanised or automatic

equipment. In semi-automatic welding, the wire feed rate and arc length are
controlled automatically, but the travel speed and wire position are under
manual control. In mechanised welding, all parameters are under automatic
control but can be varied manually during welding, eg steering of the
welding head and adjustment of wire feed speed and arc voltage. With
automatic equipment there is no manual intervention during welding. Figure
13.2 shows equipment required for the MIG/MAG process.

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Figure 13.2 MIG/MAG welding equipment.

Advantages:
Continuous wire feed.
Automatic self-regulation of the arc length.
High deposition rate and minimal number of stop/start locations.
High consumable efficiency.
Heat inputs in the range 0.1-2kJ/mm.
Low hydrogen potential process.
Welder has good visibility of weld pool and joint line.
Little or no post-weld cleaning.
Can be used in all positions (dip transfer).
Good process control possibilities.
Wide range of applications.
Disadvantages:
No independent control of filler addition.
Difficult to set up optimum parameters to minimise spatter levels.
Risk of lack of fusion when using dip transfer on thicker weldments.
High level of equipment maintenance.
Lower heat input can lead to high hardness values.
Higher equipment cost than MMA welding.
Site welding requires special precautions to exclude draughts which may
disturb the gas shield.
Joint and part access is not as good as MMA or TIG welding.
Cleanliness of base metal, slag processes tolerate greater contamination.

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13.2

Primary variables

Welding current/wire feed speed.

Voltage.
Gases.
Travel speed and electrode orientation.
Inductance.
Contact tip to work distance (CTWD).
Nozzle to work distance.
Shielding gas nozzle.
Type of metal transfer.

13.2.1 Wire feed speed

Increasing wire feed speed automatically increases the current in the wire.
Wires are generally produced in 0.6, 0.8, 1, 1.2, 1.4 and 1.6mm diameter.
13.2.2 Voltage
The most important setting in spray transfer as it controls the arc length. In
dip transfer it also affects the rise of current and the overall heat input into
the weld. Increase both wire feed speed/current and voltage will increase
heat input. Welding connections need to be checked for soundness as any
loose ones will result in resistance and cause a voltage drop in the circuit
and will affect the characteristic of the welding arc. The voltage will affect
the type of transfer achievable but this is also highly dependent on the type
of gas being used.

a)

22V

b)

23V

c)

24V

Figure 13.3 The effect of arc voltage:

a Increasing arc voltage.
b Reduced penetration, increased width.
c Excessive voltage can cause porosity, spatter and undercut.

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13.2.3 Gases

Ar

Ar-He

He

CO2

Figure 13.4 Gas composition effect on weld bead profile.

For non-ferrous metals and their alloys (such as Al, Ni and Cu) an inert
shielding gas must be used, usually pure argon or an argon rich gas with a
helium addition. The use of a fully inert gas is why the process is also called
metal inert gas (MIG) welding and for precise use of terminology this should
only be used when referring to the welding of non-ferrous metals.
The addition of some helium to argon gives a more uniform heat
concentration within the arc plasma which affects the shape of the weld
bead profile. Argon-helium mixtures give a hotter arc so are beneficial for
welding thicker base materials, those with higher, thermal conductivity, eg
copper or aluminium.
For welding all grades of steels, including stainless steels, a controlled
addition of oxygen or carbon dioxide (CO2) to generate a stable arc and give
good droplet wetting. Because these additions react with the molten metal
they are referred to as active gases, hence metal active gas (MAG) welding
is the technical term when referring to welding steels.
100%CO2
CO2 gas cannot sustain spray transfer as the ionisation potential of the gas
is too high it gives very good penetration but promotes globular droplet
transfer also a very unstable arc and lots of spatter.
Argon +15-20%CO2
The percentage of CO2 or oxygen depends on the type of steel being
welded and the mode of metal transfer used. Argon has a much lower
ionisation potential and can sustain spray transfer above 24 welding volts.
Argon gives a very stable arc, little spatter but lower penetration than CO2.
Argon and 5-20%CO2 gas mixtures give the benefit of both gases ie good
penetration with a stable arc and very little spatter. CO2 gas is much
cheaper than argon or its mixtures and is widely used for carbon and some
low alloy steels.

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Argon +1-5%CO2
Widely used for stainless steels and some low alloy steels.

Figure 13.5 Active shielding gas mixtures for MAG welding of carbon, C-Mn and
low alloy steels. Blue is a cooler and red a hotter mixture gas.

Gas mixtures with helium instead of argon give a hotter arc, more fluid weld
pool and better weld profile. These quaternary mixtures permit higher
welding speeds but may not be suitable for thin sections.
Stainless steels
Austenitic stainless steels are typically welded with argon-CO2/O2 mixtures
for spray transfer or argon-helium-CO2 mixtures for all modes of transfer.
The oxidising potential of the mixtures is kept to a minimum (2-2.5%
maximum CO2 content) to stabilise the arc but with minimum effect on
corrosion performance. Because austenitic steels have a low thermal
conductivity, the addition of helium helps to avoid lack of fusion defects and
overcome the high heat dissipation into the material. Helium additions are
up to 85%, compared with ~25% for mixtures used for carbon and low alloy
steels. CO2-containing mixtures are sometimes avoided to eliminate
potential carbon pick-up.

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Figure 13.6 Active shielding gas mixtures for MAG welding of stainless steels. Blue
is a cooler and; red a hotter gas mixture.

For martensitic and duplex stainless steels, specialist advice should be

sought. Some Ar-He mixtures containing up to 2.5%N2 are available for
welding duplex stainless steels.
Light alloys (aluminium magnesium, titanium, copper and nickel and
their alloys)
Inert gases are used for light alloys and those sensitive to oxidation.
Welding grade inert gases should be purchased rather than commercial
purity to ensure good weld quality.
Argon
Can be used for aluminium because there is sufficient surface oxide
available to stabilise the arc. For materials sensitive to oxygen, such as
titanium and nickel alloys, arc stability may be difficult to achieve with inert
gases in some applications. The density of argon is approximately 1.4 times
that of air so in the downhand position, the relatively heavy argon is very
effective at displacing air. A disadvantage is when working in confined
spaces there is a risk of argon building up to dangerous levels and
asphyxiating the welder.
Argon-helium mixtures
Argon is most commonly used for MIG welding of light alloys but an
advantage can be gained by use of helium and argon/helium mixtures.
Helium possesses a higher thermal conductivity than argon and the hotter
weld pool produces improved penetration and/or an increase in welding
speed. High helium contents give a deep broad penetration profile but
produce high spatter levels. With less than 80% argon a true spray transfer
is not possible. With globular-type transfer the welder should use a buried
arc to minimise spatter. Arc stability can be problematic in helium and
argon-helium mixtures, since helium raises the arc voltage so there is a
larger change in arc voltage with respect to arc length. Helium mixtures
require higher flow rates than argon shielding to provide the same gas
protection.
There is a reduced risk of lack of fusion defects when using argon-helium
mixtures particularly on thick section aluminium. Ar-He gas mixtures will
offset the high heat dissipation in material over about 3mm thickness.

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Figure 13.7 Inert shielding gas mixtures for MIG welding of aluminium,
magnesium, titanium, nickel and copper alloys. Blue is a cooler and red a hotter
gas mixture.

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Summary of shielding gases and mixtures used for different base materials
for MIG/MAG welding
Metal
Carbon
steel

Stainless
steels

Aluminium,
copper,
nickel,
titanium
alloys

Shielding
gas

Reaction
behaviour

Argon-CO2

Slightly
oxidising

Increasing CO2 content gives hotter arc,

improved arc stability, deeper penetration,
transition from finger-type to bowl-shaped
penetration profile, more fluid weld pool giving
flatter weld bead with good wetting, increased
spatter levels, better toughness than CO2.
Minimum 80% argon for axial spray transfer.
General purpose mixture: Argon-10-15%CO2.

Argon-O2

Slightly
oxidising

Stiffer arc than Ar-CO2 mixtures minimises

undercutting, suited to spray transfer mode,
lower penetration than Ar-CO2 mixtures, fingertype weld bead penetration at high current
levels. General purpose mixture: Argon-3%
CO2.

Ar-He-CO2

Slightly
oxidising

Substituting of helium for argon gives hotter arc,

higher arc voltage, more fluid weld pool, flatter
bead profile, more bowl-shaped and deeper
penetration profile and higher welding speeds,
compared with Ar-CO2 mixtures. High cost.

CO2

Oxidising

Arc voltages 2-3V higher than Ar-CO2 mixtures,

best penetration, higher welding speeds, dip
transfer or buried arc technique only, narrow
working range, high spatter levels, low cost.

He-Ar-CO2

Slightly
oxidising

Good arc stability with minimum effect on

corrosion resistance (carbon pick-up), higher
helium contents designed for dip transfer, lower
helium contents designed for pulse and spray
transfer. General purpose gas: He-Ar-2%CO2.

Argon-O2

Slightly
oxidising

Spray transfer only, minimises undercutting on

heavier sections, good bead profile.

Argon

Inert

Good arc stability, low spatter and generalpurpose gas. Titanium alloys require inert gas
backing and trailing shields to prevent air
contamination.

Ar-He

Inert

Higher heat input offsets high heat dissipation

on thick sections, lower risk of lack of fusion
defects, higher spatter and higher cost than
argon.

Characteristics

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13.2.4 Travel speed and electrode orientation

The faster the travel speed the less penetration, narrower bead width and
the higher risk of undercut.

Figure 13.8 The effect of travel speed. As travel speed increases, reducing
penetration and width, undercut.

Penetration
Excess weld metal
Undercut

Deep
Maximum
Severe

Moderate
Moderate
Moderate

Shallow
Minimum
Minimum

Figure 13.9 Effect of torch angle.

13.2.5

Effect of contact tip to workpiece distance

CTWD has an influence over the welding current because of resistive
heating in the electrode extension (Figure 13.10). The welding current
required to melt the electrode at the required rate to match the wire feed
speed reduces as the CTWD is increased. Long electrode extensions can
cause lack of penetration, for example, in narrow gap joints or with poor
manipulation of the welding gun. Conversely, the welding current increases
when the CTWD is reduced. This provides the experienced welder with a
means of controlling the current during welding but can result in variable
penetration in manual welding with a constant voltage power source.
As the electrode extension is increased the burn-off rate increases for a
given welding current due to increased resistive heating. Increasing the
electrode extension, eg in mechanised applications, is therefore one way of

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increasing deposition rates, as the wire feed speed is increased to maintain

the required welding current.

Contact tip

Gas nozzle
Contact tip
setback
Electrode
extension

Nozzle-towork (standoff) distance

Arc length

Contact
tip to work
distance

Workpiece
Figure 13.10 Contact tip to workpiece distance; electrode extension and nozzle to
workpiece distance.

Resistive heating depends on the resistivity of the electrode, the electrode

extension length and wire diameter so is more pronounced for welding
materials which have high resistivity, such as steels. The electrode
extension should be kept small when small diameter wires are being used to
prevent excessive heating in the wire and avoid the resulting poor bead
shape.
Stable condition

Sudden change in gun position

Arc length L = 6,4mm
Arc voltage = 24V
Welding current = 250A

19mm

Arc length remains

the same, but
welding current
decreases

Figure 13.11 Effect of increasing the contact tip to workpiece distance. Arc length
remains same length.

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Increased extension
Figure 13.12 Effect of increasing electrode extension.

At short CTWDs, radiated heat from the weld pool can cause overheating of
the contact tube and welding torch which can lead to spatter adherence and
increased wear of the contact tube.
The electrode extension should be checked when setting-up welding
conditions or fitting a new contact tube. Normally measured from the contact
tube to the workpiece (Figure 13.13) suggested CTWDs for the principal
metal transfer modes are:
Metal transfer mode

CTWD, mm

Dip

10-15

Spray

20-25

Pulse

15-20

Contact tip
extension
(0-3.2mm)

Electrode
extension
6-13mm

Set up for Dip transfer

Electrode
extension
19-25mm

Contact tip
recessed
(3-5mm)

Set up for Spray transfer

Figure 13.13 Suggested contact tip to work distance.

Figure 13.13 Suggested contact tip to work distance.

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13.2.6

Effect of nozzle to work distance

Nozzle to work distance (Figure 13.13) has a considerable effect on gas
shielding efficiency with a decrease stiffening the column. The nozzle to
work distance is typically 12-15mm. If the CTWD is simultaneously reduced,
however, the deposition rate at a given current is decreased and visibility
and accessibility are affected; so in practice a compromise is necessary.
The following gives suggested settings for the mode of metal transfer being
used.
Metal transfer mode

Contact tip position relative to nozzle

Dip

2mm inside to 2mm protruding

Spray

4-8mm inside

Spray (aluminium)

6-10mm inside

13.2.7 Shielding gas nozzle

The purpose of the shielding gas nozzle is to produce a laminar gas flow to
protect the weld pool from atmospheric contamination. Nozzle diameters
range from 13-22mm and should be increased in relation to the size of the
weld pool. Therefore, larger diameter nozzles are used for high current,
spray transfer application and smaller diameter for dip transfer. The flow
rate must also be tuned to the nozzle diameter and shielding gas type to
give sufficient weld pool coverage. Gas nozzles for dip transfer welding tend
to be tapered at the outlet of the nozzle.
Joint access and type should also be considered when selecting the
required gas nozzle and flow rate. Too small a nozzle may cause it to
become obstructed by spatter more quickly and if the wire bends on leaving
the contact tube, the shielding envelope and arc location may not coincide.
13.2.8

Types of metal transfer

Arc Voltage, V

Welding Current, A
Figure 13.14 Arc characteristic curve.

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Key characteristics of dip transfer

Metal transfer by wire dipping or short-circuiting into the weld pool.
Relatively low heat input process.
Low weld pool fluidity.
Used for thin sheet metal above 0.8mm and typically less than 3.2mm,
positional welding of thicker section and root runs in open butt joints.
Process stability and spatter can be a problem if poorly tuned.
Lack of fusion of poorly set-up and applied.
Not used for non-ferrous metals and alloys.

Figure 13.15 Dip transfer.

In dip transfer the wire short-circuits the arc 50-200 times/second and this
type of transfer is normally achieved with CO2 or mixtures of CO2 and argon
gas + low amps and welding volts <24V.
Key characteristics of spray transfer
Free-flight metal transfer.
High heat input.
High deposition rate.
Smooth stable arc.
Used on steels above 6mm and aluminium alloys above 3mm thickness.

Figure 13.16 Spray transfer.

Spray transfer occurs at high currents and voltages. Above the transition
current, metal transfer is a fine spray of small droplets projected across the

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arc with low spatter levels. The high welding current produces strong
electromagnetic forces (pinch effect) that cause the molten filament
supporting the droplet to neck down. Droplets detach from the tip of the wire
and accelerate across the arc gap. The frequency with which the droplets
detach increases with the current. The droplet size equates to the wire
diameter at the threshold level but decreases significantly as the welding
current increases. At very high currents (wire feed speeds), the molten
droplets can start to rotate (rotating transfer). The arc current is flowing
during the drop detachment resulting in maximum penetration and a high
heat input. When the correct arc voltage to give spray transfer is used, the
arc is short with the wire tip 1-3mm from the surface of the plate.
With steels it can be used only in downhand butts and H/V fillet welds but
gives higher deposition rate, penetration and fusion than dip transfer
because of the continuous arc heating. It is mainly used for steel plate
thicknesses >3mm but has limited use for positional welding due to the
potential large weld pool involved.
Key characteristics pulsed transfer:
Free-flight droplet transfer without short-circuiting over the entire working
range.
Very low spatter.
Lower heat input than spray transfer.
Reduced risk of lack of fusion compared with dip transfer.
Control of weld bead profile for dynamically loaded parts.
Process control/flexibility.
Enables use of larger diameter, less expensive wires with thinner plates
more easily fed (particular advantage for aluminium welding).
Pulsing the welding current extends the range of spray transfer operation
well below the natural transition from dip to spray transfer. This allows
smooth, spatter-free spray transfer at mean currents below the transition
level, eg 50-150A and at lower heat inputs. Pulsing was introduced originally
to control metal transfer by imposing artificial cyclic operation on the arc
system by applying alternately high and low currents.
A typical pulsed waveform and the main pulse welding variables are shown
in Figure 13.17. A low background current (typically 20-80A) is supplied to
maintain the arc, keep the wire tip molten, give stable anode and cathode
roots and maintain average current during the cycle. Droplet detachment
occurs during a high current pulse at current levels above the transition
current level. The pulse of current generates very high electromagnetic
forces which cause a strong pinch effect on the metal filament supporting
the droplet the droplet is detached and projected across the arc gap. Pulse
current and current density must be sufficiently high to ensure that spray
transfer (not globular) always occurs so that positional welding can be used.
Pulse transfer uses pulses of current to fire a single globule of metal across
the arc gap at a frequency of 50-300 pulses/second. It is a development of

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spray transfer that gives positional welding capability for steels, combined
with controlled heat input, good fusion and high productivity and may be
used for all sheet steel thickness >1mm, but is mainly used for positional
welding of steels >6mm.

Figure 13.17 Pulsed welding waveform and parameters.

Key characteristics of globular transfer:

Irregular metal transfer.
Medium heat input.
Medium deposition rate.
Risk of spatter.
Not widely used in the UK can be used for mechanised welding of
medium thickness (typically 3-6mm) steel in the flat (PA) position.
The globular transfer range occupies the transitional range of arc voltage
between free-flight and fully short-circuiting transfer. Irregular droplet
transfer and arc instability are inherent, particularly when operating near the
transition threshold. In globular transfer a molten droplet several times the
electrode diameter forms on the wire tip, gravity eventually detaches it when
its weight overcomes surface tension forces and transfer takes place often
with excessive spatter. Before transfer the arc wanders and its cone covers
a large area, dissipating energy.
There is a short duration short-circuit when the droplet contacts with the
molten pool but rather than causing droplet transfer it occurs as a result of it.
Although the short-circuit is of very short duration, some inductance is
necessary to reduce spatter, although to the operator the short-circuits are
not discernible and the arc has the appearance of a free-flight type.
To further minimise spatter levels, it is common to operate with a very short
arc length and in some cases a buried arc technique is adopted. Globular
transfer can only be used in the flat position and is often associated with
lack of penetration, fusion defects and uneven weld beads because of the
irregular transfer and tendency for arc wander.

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13.2.9 Inductance
When MIG/MAG welding in the dip transfer mode, the welding electrode
touches the weld pool causing a short-circuit during which the arc voltage is
nearly zero. If the constant voltage power supply responded instantly, very
high current would immediately begin to flow through the welding circuit and
the rapid rise in current to a high value would melt the short-circuited
electrode free with explosive force, dispelling the weld metal and causing
considerable spatter.

Current

Inductance is the property in an electrical circuit that slows down the rate of
current rise (Figure 13.18). The current travelling through an inductance coil
creates a magnetic field which creates a current in the welding circuit in
opposition to the welding current. Increasing inductance will also increase
the arc time and decrease the frequency of short-circuiting.

Figure 13.18 Relationship between inductance and current rise.

There is an optimum value of inductance for each electrode feed rate,. Too
little results in excessive spatter, too much and current will not rise fast
enough and the molten tip of the electrode is not heated sufficiently causing
the electrode to stub into the base metal. Modern electronic power sources
automatically set inductance to give a smooth arc and metal transfer.

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13.3

MIG basic equipment requirements

1

10

8
3
7
4

6
11
12
13
14
15
16
17
18
19
20

5
Power source-transformer/rectifier (constant voltage type).
Inverter power source.
Power hose assembly (liner, power cable, water hose, gas hose).
Liner.
Spare contact tips.
Torch head assembly.
Power-return cable and clamp.
15kg wire spool (copper coated and uncoated wires).
Power control panel.
External wire feed unit.

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The MIG/MAG wire drive assembly

Internal wire drive system.
1

Flat plain top drive roller.

Wire guide.

Groove half bottom drive roller.

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The MIG torch head assembly

1
2
3
7

1
2
3
4
5
6
7

Torch body.
On/off or latching switch.
Spot welding spacer attachment.
Contact tips.
Gas diffuser.
Gas shrouds.
Torch head assembly (minus the shroud).

13.4

Inspection when MIG/MAG welding

13.4.1

Welding equipment
Visual check to ensure the welding equipment is in good condition.

13.4.2 Electrode wire

The diameter, specification and quality of wire are the main inspection
headings. The level of de-oxidation of the wire is an important factor with
single, double and triple de-oxidised wires being available.

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The higher the level of de-oxidants in the wire, the lower the chance of
porosity in the weld. The quality of the wire winding, copper coating and
temper are also important factors in minimising wire feed problems.
Quality of wire windings and increasing costs
a) Random wound. b) Layer wound. c) Precision layer wound.
13.4.3 Drive rolls and liner
Check the drive rolls are the correct size for the wire and that the pressure is
hand tight or just sufficient to drive the wire. Excess pressure will deform the
wire to an ovular shape making it very difficult to drive through the liner,
resulting in arcing in the contact tip and excessive wear of the contact tip
and liner.
Check that the liner is the correct type and size for the wire. One size of liner
generally fits two sizes of wire, ie 0.6 and 0.8, 1 and 1.2, 1.4 and 1.6mm
diameter. Steel liners are used for steel wires and Teflon for aluminium
wires.
13.4.4

Contact tip
Check the contact tip is the right size for the wire being driven and the
amount of wear frequently. Any loss of contact between the wire and contact
tip will reduce the efficiency of current pick. Most steel wires are copper
coated to maximise the transfer of current by contact between two copper
surfaces at the contact tip but this also inhibits corrosion. The contact tip
should be replaced regularly.

13.4.5

Connections
The electric arc length in MIG/MAG welding is controlled by the voltage
settings, achieved by using a constant voltage volt/amp characteristic inside
the equipment. Any poor connection in the welding circuit will affect the
nature and stability of the electric arc so is a major inspection point.

13.4.6 Gas and gas flow rate

The type of gas used is extremely important to MIG/MAG welding, as is the
flow rate from the cylinder which must be adequate to give good coverage
over the solidifying and molten metal to avoid oxidation and porosity.
13.4.7

Other variable welding parameters

Checks should be made for correct wire feed speed, voltage, speed of travel
and all other essential variables of the process given on the approved
welding procedure.

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13.4.8

Safety checks
Checks should be made on the current carrying capacity or duty cycle of
equipment and electrical insulation. Correct extraction systems should be
used to avoid exposure to ozone and fumes.
A check should always be made to ensure that the welder is qualified
to weld the procedure being used.
Typical welding imperfections
Silica inclusions on ferritic steels only caused by poor inter-run cleaning.
Lack of sidewall fusion during dip transfer welding of thick section
vertically down.
Porosity caused by loss of gas shield and low tolerance to contaminants.
Burn-through from using the incorrect metal transfer mode on sheet
metal.

13.5

Flux-cored arc welding (FCAW)

In the mid-1980s the development of self-and gas-shielded FCAW was a
major step in the successful application of on-site semi-automatic welding
and has enabled a much wider range of materials to be welded.
The cored wire consists of a metal sheath containing a granular flux which
can contain elements normally used in MMA electrodes so the process has
a very wide range of applications.
In addition, gas producing elements and compounds can be added to the
flux so the process can be independent of a separate gas shield, which
restricts the use of conventional MIG/MAG welding in many field
applications.
Most wires are sealed mechanically and hermetically with various forms of
joint. The effectiveness of the were joint is an inspection point of cored wire
welding as moisture can easily be absorbed into a damaged or poor seam.
Wire types commonly used are:

Rutile which give good positional capabilities.

Basic also positional but good on dirty material.
Metal-cored higher productivity, some having excellent root run
capabilities.
Self-shielded no external gas needed.

Baking of cored wires is ineffective and will not restore the condition of a
contaminated flux within a wire.

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Note: Unlike MMA electrodes the potential hydrogen levels and mechanical
properties of welds with rutile wires can equal those of the basic types.

13.6

Summary of solid wire MIG/MAG

Equipment requirements
Transformer/rectifier (constant voltage type).
Power and power return cable.
Inert, active or mixed shielding gas (argon or CO2).
Gas hose, flow meter and gas regulator.
MIG torch with hose, liner, diffuser, contact tip and nozzle.
Wire feed unit with correct drive rolls.
Electrode wire to correct specification and diameter.
Correct visor/glass, safety clothing and good extraction.
Parameters and inspection points
Wire feed speed/amperage.
Open circuit and welding voltage.
Wire type and diameter.
Gas type and flow rate.
Contact tip size and condition.
Roller type, size and pressure.
Liner size.
Inductance settings.
Insulation/extraction.
Connections (voltage drops).
Travel speed, direction and angles.
Typical welding imperfections
Silica inclusions.
Lack of fusion (dip transfer).
Surface porosity.
Advantages and disadvantages
Advantages

Disadvantages

High productivity

Lack of fusion (dip transfer)

Easily automated

Small range of consumables

All positional (dip, pulse and FCAW)

Protection for site working

Material thickness range

Complex equipment

Continuous electrode

High ozone levels

13-22

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