MIG MAG Welding Guide For Gas Metal Arc Welding

GAS METAL ARC WELDING GUIDE

• 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
• 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