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12.08.

2003 1

MIG CO2 Welding Process
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Advantages of MIG Co
2
welding
over stick arc welding (SMAW)
1. Higher weld metal deposition rate.
2. Less heat input, hence decrease
distortion.
3. High weld metal recovery, hence
economical.
4. As there is no flux, weld deposit is
visible during welding process, hence
better control on welding.
5. Elimination of atmospheric
contamination gives stronger and
more consistent weld.
6. No entrapment of slag (While using
solid wire).
7. Little or no post weld clean up.
8. Large gaps can be filled easily.
9. Thin weld can be easily welded.
10.Can be used in all positions.
11.Less skill required.
12.Choice of weld metal transfer mode
available.

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Disadvantages of MIG Co
2

process
1. Drafty conditions can blow the shielding
gas away.
2. Cold lapping can happen low heat
input melts wire but not the work piece.
3. Equipment is more expensive and less
portable compared to SMAW.
4. High level of radiated light, heat and arc
intensity can be uncomfortable for some
operators.
5. More prone to poor penetration during
high welding speed.

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MIG Co
2
Welding Machine &
Accessories
MIG Co
2
Welding Setup.
The machine consists of;
a. Power Source
b. Wire Feeder
c. Welding Torch.
Gas
a. Gas Cylinder
b. Gas Regulator
c. Heater
Accessories
1. Protective equipment

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Selection of power source
1. Out put Current at 100% duty cycle.
2. Class of insulation.
3. Core winding (Aluminium or Copper).
4. Power consumption.
Types of power source.
1. Silicon Diod
2. Thyristor
3. Inverter
Advantages of inverter;
1. Smooth arc.
2. Low spatter.
3. Finer controls.
4. Low power consumption.
5. AC/DC out put from same source.
MIG Co
2
Welding Machine &
Accessories
Types of wire feeder
1. 2 rolls drive
2. 4 rolls drive
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MIG Co
2
Welding Machine &
Accessories
Functions of welding torch
1. Guiding the welding wire.
2. Carrying the shielding gas to
the weld pool.
3. Carrying the welding current
to the contact tip.
4. Circulating water for cooling.
(Heavy duty welding).

Types of welding torches:
1. Air-cooled.
2. Water-cooled.
Shade Number Current Amps
10 Under 80
11 80 - 125
12 125 - 175
13 175 - 300
14 300 - 500
15 Over 450
Recommended shade number of
filter for MIG Co
2
welding
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Shielding Gases
Shielding gases used in MIG Co

1. Carbon Dioxide.
2. Mixed gases, prime gas being Argon.
Effect of shielding gas on the
weld bead profile.
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Weld-Metal Transfer Mode
Principal modes of weld metal transfer.
1. Spray
2. Pulsed
3. Dip or short circuit
4. Globular
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Weld-Metal Transfer Mode
Fig.3 Spray Transfer
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Weld-Metal Transfer Mode
Pulsed arc metal transfer.
following variables:
1. Frequency The number of times
the current is raised and lowered
to form a single pulse. Frequency
is measured in pulses per second.
2. Amplitude The amperage or
current level of power at the peak
or maximum, expressed in
amperage
3. Width of the pulses The amount
of time the amperage is allowed to
stay on.
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Weld-Metal Transfer Mode
Short Circuit or Dip Transfer
Globular Transfer
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Parameter setting
Wire melting and deposition rate.
Deposition efficiency
M = Weight of Weld Deposit
E = Weight of welding electrode consumed
D
=
M
--- x 100
E
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Parameter setting
Welding power supply
Molten weld pool control
The GMAW molten weld pool can
be controlled by varying.
Shielding gas
Power setting
Weave pattern
Travel speed
Electrode extension
Gun angle.
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Parameter setting
Electrode extension (stick-out)
Heat buildup
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Parameter setting
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Welding techniques
Back hand
Fore hand
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MIG Co
2
Welding wire (Solid)
Cast & Helix
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Flux cored welding wire
Manufacturing process
Cross section of the wire
Types of wires

Rutile
Basic
Metal cored
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Flux cored welding wire
Flux contains the following agents,
Deoxidisers
Slag formers
Fluxing agents
Arc stabilizers
Alloying elements
Function of slag formers
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Flux cored wire advantages &
disadvantages
High deposition rate
Minimum electrode waste
Less edge preparation
Minimum pre-cleaning
All position
Flexibility
Excellent control