MIG welding is also known as “gas metal arc welding.” MIG welding parameters play a critical role in the final quality, productivity, and cost of welding operations. So it is crucial to know whether your MIG welder is set for optimum performance or not. Suppose you’re an experienced welder looking to refresh your knowledge or a hobbyist wanting to learn how to set up a MIG welder, then this post is for you.
Due to its popularity and ease of operation, MIG welding is the favorite choice of newbies and professional welders.
Here’s a brief guide about the MIG welder setting.
Introduction to MIG Welding
Generally, we call it MIG welding. MIG means “metal inert gas.” We call it GMAW( gas metal arc welding) in the industry.
The process is simple: a positively charged wire electrode and grounded workpiece produce an electrical arc when we supply voltage. The heat produced in this process melts the electrode and surrounding metal of the workpiece. This molten pool forms the welded joint when it cools. An inert gas emitted from the torch tip surrounds this process and prevents oxygen from entering. This way, inert gas stabilizes the process by successfully stopping the contamination from atmospheric air.
Before Proceeding towards MIG Welder Setup
Before diving into pressing dials and making settings, let’s have short know-how of different components of the MIG welder, their operations, and considerations to ensure proper setup.
Selection of the right equipment
Always go for the right choice depending on the quantity of work. Simple MIG welders are best suited to occasional welding operations, while multi-process welders are good for varying welding capabilities. Different types are available in the market according to your need at home or in the shop.
Selecting the right material
Material type is the critical factor as different materials have different properties, so each requires separate settings of parameters in MIG welding. Mostly three types of workpieces are used.
- Carbon steel
- Stainless steel
Different properties result in melting point differences, so is the heat requirement. As a result, we use different settings.
Other parameters that affect the workpiece setup
Other factors like the thickness of the workpiece and type of filler or electrode also affect the settings of parameters. The types of gas and electrode depend on material type and thickness. Thicker metal affects the quality of the joint as a thicker workpiece requires more heat for the weld to penetrate deep enough.
How to Set up the MIG welder
For setting up the MIG welder, we need to understand the main settings that need to be controlled before making any weld. These settings are done once the workpiece is ready and clamped properly.
- Voltage level
- Feed wire and its feeding rate
- Shielding gas
The voltage level is the major parameter for controlling the arc length and heating capability. But in a MIG welder, a constant positive electrode voltage is used. Its value is constant and never changes for majority operations in the case of MIG welding. Different transformers and rectifiers are used to stabilize the continuous voltage supply.
Voltage level determines arc length, height, and width of the bead, so proper voltage setting is necessary. Different charts are available to set the voltage level.
Feed wire setting
Voltage is constant for MIG welders, so the feed wire setup is the major control parameter, controlling amperage and weld penetration levels. We denote it by inches per minute. The Thicker the metal more is the amperage required. Select a wire size depending upon the need. A thick wire is selected for thicker metal. At the same time, a thin wire is chosen to slow the wire feed rate for better quality welds instead of decreasing the feed rate too low for thicker wire.
Too high wire feed leads to burn through, and a very low rate results in weak welds. Maintain a specified distance between the electrode and MIG gun tip for fine welding. Try to check it after a while to ensure consistent results.
When it comes to shielding gas, we are interested in knowing its flow rate, volume, and type to determine the transfer type. We get the result by combining this factor with voltage level and wire feeds. There are no fixed criteria for the pressure of the gas. It is usually based on a trial and error method to judge a compatible range.
A pressure range of 18-22 CFM is fine in normal conditions. It all depends on the surrounding states; for example, a drafty area requires pressure greater than 35 CFM. The main purpose of this gas is to protect the weld from contamination due to atmospheric oxygen. Too high pressure might contaminate the weld due to turbulency as air is sucked into the weld area. A low quantity of shielding gas leads to porosity in the weld area.
Choosing the right helmet for welding
Choice of a helmet is an important factor whether you’re a pro or a newbie welder. Although some old versions of helmets are still in use, modern helmets offer much ease during welding and provide accuracy and a feeling of fulfillment even to beginners. So, which is the best welding helmet for beginners?
This question might intrigue you because newbies often find it difficult to choose one that is affordable and of high quality. Len,s shade determines helmet usage. For amperage greater than 200, use a shade helmet and 8-9 for below 200.
Additional considerations for boosting overall efficacy
If you’re wondering how to set up a MIG welder, use a combined set of above listed three factors to getting the desired results. Familiarize yourself with these steps and practice them to get a deep understanding. In this way, you can easily set up your MIG welding machine.
To boost the efficacy, always start with reading and understanding the manual that the company offers with their machine. Using the manual, you can better understand the procedures and operations of machines and technicalities, which may be different for different companies. Manuals also contain safety guidelines and charts for optimum performance in different scenarios.
Always take proper care of maintenance and repair work that your equipment needs to perform better. Check for leaks once you turn on the gas. Apply the soapy solution to detect leaks. Repair any damage or worn-out wires at first glance of spotting them. Check whether all the components are working or not. Follow all the safety guidelines to avoid any inconvenience.
The three major factors we listed above help you get familiarized with how to set up a MIG welding machine. There is no shortcut to achieving mastery unless you practice consistently to live up to your expectations. Inspection after every weld and checking by doing it on scrap metal helps a lot.
Why it is recommended to have a clean joint?
The answer is simple,
Dirty joint leads to spattering that might start the fire.
Also, machine settings vary for clean and dirty joints.
A good weld results from a clean joint.
How can you identify the lack of shielding gas?
You can easily identify the lack of shielding gas by looking at the face of the weld, as the lack of gas leads to porosity and pinholes in the final weld. Check the regulator and increase the flow as per need. Also, check for any leaks as well.
What is travel speed, and how does it differ from wire speed?
Travel speed defines the rate at which you’re moving the welder torch to wed the joint. Although it differs from wire speed, both are dependent on each other. A specific travel speed is mandatory for a set wire speed, neither too fast nor too slow to get a quality weld.
Is MIG welding hard to learn?
MIG welding is not hard to learn, but it does require some practice to get the hang of it. The most important thing to remember is to keep the welding gun at a consistent distance from the workpiece, and to always use a shielding gas to protect the weld from contamination.
Do you push or pull a MIG welder?
It depends on the type of MIG welder. Some MIG welders are push-type welders, and some are pull-type welders.
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