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MIG WELDING | MIG WELDER COMPONENTS | OPERATING THE MIG WELDER | METAL TRANSFER MODES

Posted on | January 5, 2011 | No Comments

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How Does an MIG Welder Operate?

     MIG Welding

  1. Welding is the joining together of two separate metal pieces with the use of extremely high heat, produced by an electric current, or arc. MIG (metal inert gas) welders work by feeding wire and gas simultaneously through a welding machine or gun. The wire and gas are fed continuously, because they are consumed continuously by the act of welding. The gas is an inert gas, and is used to protect or shield the area being welded from other gases that are present. The gas displaces the air around the weld. Four types of metal contact or transfer exist: short-circuiting, pulsed-spray, spray and globular.

    MIG Welder Components

  2. The parts that make up a MIG welding unit are the control switch, the power source, the wire feed, the welding torch (or gun), the electrode or wire source and the gas supply. The torch is where all the parts come together for welding. The nozzle houses a gas diffuser and a contact tip, which has an opening that allows the electrode (wire) to move out of the gun. Pieces in the torch nozzle must be able to sustain very high levels of heat during the welding process; therefore the pieces in the nozzle are usually made of molded thermoset plastics, which do not soften.

    Operating The MIG Welder

  3. Voltage, gas and electrode must be chosen for the type of metal being welded. In MIG welders, Argon is usually the gas of choice. By pressing the control switch, the electrode is fed into the machine, and the welding begins. Letting go of the control switch stops the welding. The contact tip inside the nozzle is usually copper, and is connected to the power source. The contact tip guides the electrode to the pieces being welded. Because it is connected to the power source, the contact tip transmits the electrical current to the electrode as it also guides it. The arc is created between the electrode and the metal to be welded. The seam or stream of molten metal is not deposited until the electrode touches the metal.

    Metal Transfer Modes

  4. Each transfer mode requires different electrodes, currents and gases. Globular metal transfer uses carbon dioxide, and is used for flat steel surfaces, and when cost is an issue. Short-circuit metal transfer uses a low current, smaller wire and carbon dioxide, and is used only on ferrous materials, producing a much cleaner weld than the globular transfer. Pulsed spray uses Argon gas with the addition of a low level of carbon dioxide. Larger wire can be used, and the process works on almost all metals. It does, however, require a special power supply that can produce pulsed currents.

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