travel speed welding mig

How to Calculate Travel Speed in Mig Welding: A Comprehensive Guide

How to calculate travel speed in mig welding.

To calculate travel speed in MIG welding, you need to use the Travel Speed calculator.

This calculator uses the time taken to complete the weld, the weld length, welding amps, and volts to determine the travel speed.

It utilizes two formulas to calculate the heat input.

It is important to calculate the travel speed accurately to ensure proper feed speed in MIG welding.

Improper feed speed can result in weak weld joints or burn holes in the metal.

MIG welding machines automatically feed wire through the torch head to the weld site, and the wire acts as the electrode to create the weld bead and filler material.

The MIG wire must be fed at the appropriate speed to ensure a proper joint is created.

Did You Know?

1. The speed of travel in MIG welding is typically measured in inches per minute (IPM) or centimeters per minute (CPM). However, did you know that the optimal travel speed can vary depending on the material being welded? For example, when welding aluminum, the travel speed should be slower compared to welding steel or stainless steel.

2. One factor that can affect travel speed in MIG welding is the welding position. It is generally easier and faster to weld in the flat or horizontal positions compared to vertical or overhead positions. So, if you’re looking to increase your travel speed, try to weld in a favorable position whenever possible.

3. Travel speed can have a significant impact on the quality of the weld. Welding too slowly can result in excessive heat input, leading to distortion, burn-through, or lack of fusion. Conversely, welding too fast can result in insufficient heat input, causing poor penetration and weak welds. Therefore, finding the right balance and maintaining a consistent travel speed is crucial for achieving high-quality welds.

4. The type and size of the welding wire you use can also influence the travel speed in MIG welding. Thicker wires typically require higher travel speeds, while thinner wires require slower travel speeds. Additionally, selecting the proper wire feed speed and voltage settings for your specific wire diameter can help optimize travel speed and overall welding performance.

5. It’s important to note that travel speed is not the sole determinant of productivity in MIG welding. Other factors, such as proper joint preparation, suitable shielding gas, and appropriate welding techniques, also play a significant role. Keeping these aspects in mind and adjusting the travel speed accordingly can help you achieve efficient and high-quality MIG welds.

Introduction To Travel Speed Calculator In Mig Welding

MIG welding , also known as Gas Metal Arc Welding (GMAW) , is a versatile welding process widely used in various industries. The travel speed calculator is an essential tool that aids in determining the optimal travel speed for MIG welding.

By finding the right travel speed , welders can ensure the creation of strong and durable weld joints. The calculator requires specific inputs, including:

• The time taken to complete the weld
• The length of the weld
• Welding amps

With this information, the calculator employs two formulas to calculate the heat input , which is a crucial factor in determining the travel speed.

Required Inputs For Travel Speed Calculation

To effectively utilize the travel speed calculator, the following key inputs must be provided:

• Time taken to complete the weld : This refers to the duration it takes to finish the welding process.
• Length of the weld : It is the distance that needs to be covered during welding.
• Welding amps and volts : These represent the electrical parameters set on the welding machine. These values directly impact the heat input and consequently determine the travel speed.

Accurate measurements and data are crucial for the calculator to provide reliable results.

The Importance Of Heat Input Calculation In Mig Welding

The heat input calculation in MIG welding is crucial for ensuring the quality and integrity of the weld joint. It refers to the total amount of heat energy transferred to the weld, and is a critical parameter in determining the proper travel speed needed to achieve a sound weld .

Accurate heat input calculation is vital to ensure that the weld metal is adequately melted and fused together. Incorrect calculations can result in incomplete fusion or overheating , leading to weak weld joints and potential failure under stress.

The travel speed calculator utilizes the heat input calculation to determine the optimal travel speed , which greatly contributes to the overall success and durability of the welded joint.

– Importance of heat input in MIG welding:

• Determines quality and integrity of weld joint
• Critical for achieving a sound weld
• Ensures adequate melt and fusion of weld metal

– Consequences of incorrect heat input calculation:

• Incomplete fusion or overheating
• Weak weld joints
• Potential failure under stress

– Utilization of travel speed calculator:

• Determines optimal travel speed
• Enhances overall success and durability of weld joint

“The heat input calculation in MIG welding is of utmost importance as it directly affects the quality and integrity of the weld joint.”

Effects Of Improper Feed Speed In Mig Welding

Proper feed speed is crucial in MIG welding as improper feeding can have detrimental effects on the resulting weld joint. Inadequate wire feed speed , either too slow or too fast , can lead to various issues such as weak weld joints or burn holes in the metal.

Insufficient wire feed speed can result in a lack of proper fusion between the weld metal and the base metal. This can lead to weak weld joints that are prone to failure under stress . On the other hand, excessive wire feed speed can create excessive heat , causing burn holes in the metal.

It is essential to ensure that the wire feed speed is at an appropriate level to guarantee the creation of a sound and durable weld joint . The travel speed calculator aids in determining the suitable wire feed speed by considering the specific parameters and requirements of the welding process.

Understanding The Role Of Mig Wire In Creating Weld Joints

In MIG welding , the wire acts as the electrode , creating the weld bead and serving as the filler material to join metal pieces. The MIG wire plays a critical role in the welding process, as it determines the composition and strength of the weld joint.

The MIG wire must be carefully selected based on the materials being welded and the desired mechanical properties. Different types of MIG wires, such as solid wires and flux-cored wires , have various applications and advantages. Solid wires are commonly used for welding mild steel , while flux-cored wires are suitable for welding in outdoor or windy conditions .

Understanding the role of the MIG wire allows welders to select the appropriate wire for the job at hand, ensuring optimal performance and strong weld joints .

• MIG welding uses the wire as the electrode, weld bead, and filler material.
• The composition and strength of the weld joint depend on the MIG wire selected.
• Different types of MIG wires, such as solid and flux-cored wires, have specific applications.
• Solid wires are suitable for welding mild steel, while flux-cored wires are ideal for outdoor or windy conditions.

“The MIG wire determines the composition and strength of the weld joint.”

Significance Of Proper Wire Feed Speed In Mig Welding

Proper wire feed speed is crucial in MIG welding as it directly impacts the quality and strength of the weld joint. The wire must be fed at the correct speed to ensure the creation of a proper joint.

If the wire feed speed is too slow , there may be insufficient filler material to adequately fill the weld joint, resulting in weak or incomplete fusion . Conversely, if the wire feed speed is too fast , excessive heat may be produced, potentially leading to burn-through or distortion .

By utilizing the travel speed calculator , welders can determine the appropriate wire feed speed needed for a particular welding project. This ensures the creation of strong, durable, and high-quality weld joints that meet industry standards and requirements .

In conclusion , the travel speed calculator plays a vital role in MIG welding by helping calculate the optimal travel speed . Accurate inputs and calculations aid in determining the appropriate heat input , which directly influences the quality and strength of the weld joint. By understanding the significance of proper wire feed speed and selecting the appropriate MIG wire , welders can ensure the creation of sound and durable weld joints .

Frequently Asked Questions

How do you calculate mig welding speed.

To calculate MIG welding speed, you need to multiply the required amperage of the weld by the burn rate associated with the wire’s diameter. For instance, if the required amperage is 125 amps and the wire’s burn rate is 2 inches, the feed speed can be calculated as 250 inches per minute. This formula helps determine the appropriate feed speed for achieving the desired welding result.

What is the formula for travel speed in welding?

The formula for travel speed in welding can be determined by dividing the length traveled (l) by the time taken (t) to travel that length. In this case, with a length (l) of 150 mm and a time (t) of 68 s, the travel speed can be calculated as 150 mm / 68 s = ~2.2 mm/s or 132 mm/min. Therefore, the formula for travel speed in welding is l / t.

What is the formula for travel speed?

The formula for calculating travel speed is derived from the relationship between distance travelled and the time taken. By dividing the distance by the time, we can determine the average speed at which an object has traveled. This relationship is represented in the formula: speed = distance ÷ time. By applying this formula, we can quantify and understand the speed at which objects move in relation to the distance covered and the time it took.

How do you calculate MIG welding parameters?

To calculate MIG welding parameters, it is crucial to understand the relation between material thickness and required output amperage. As a rule of thumb, for every .001 inch of material thickness, 1 amp of output is needed. For instance, a .125 inch thickness warrants 125 amps for optimum welding performance. Thus, determining the appropriate wire size becomes pivotal and should be chosen accordingly to match the designated amperage for a successful MIG welding operation.

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Mig Welder Settings [We Explain The Ones You Need]

Whether you’re new to welding or an experienced welder looking to refine your skills, understanding your MIG welders settings is crucial. In this article, we’ll break down the key factors that govern MIG welding—a process that joins metal with precision and skill.

What are the most important mig welder settings? The most important MIG welder settings are voltage, wire feed speed, and shielding gas flow rate. These settings determine the heat, wire deposition rate, and protection from atmospheric contamination, respectively, crucial for producing strong and clean welds.

As we go along, you’ll learn how to balance voltage and wire feed speed for consistent, strong welds. We’ll also explain the significance of shielding gas flow rates and how they protect your welds.

Additionally, we’ll discuss how material thickness, welding position, and the type of welding wire impact your MIG welder settings.

Don’t worry if it sounds complex right now; we’ll guide you step by step. So, let’s dive into the practical world of MIG Welder Settings. By the end of this article, you’ll have the knowledge to confidently configure your MIG welder for various projects, creating reliable and professional-quality welds.

Understanding Your Mig Welder

When it comes to Mig welding, familiarity with your welding machine is the first step towards success.

A typical Mig welder consists of several crucial components that work in harmony to create those strong, precise welds you’re aiming for.

Understanding these components will provide you with a solid foundation for adjusting your Mig welder settings effectively.

• Power Source: This is the heart of your Mig welder, supplying the electrical energy needed for welding. It’s usually connected to a standard power outlet, and its output can be adjusted to suit your welding needs.
• Wire Feeder: The wire feeder is responsible for feeding the welding wire through the welding gun. It ensures a constant, controlled flow of wire during welding, a key factor in maintaining a stable arc.
• Welding Gun: The welding gun is your point of control, where you direct the arc to create the weld. It houses the contact tip, which makes contact with the workpiece and initiates the electrical arc.
• Gas Regulator and Flowmeter: If you’re using shielding gas for your Mig welding, you’ll find these components crucial. The gas regulator controls the pressure of the shielding gas, while the flowmeter lets you monitor and adjust the gas flow rate.

Understanding certain key terms is essential for making informed decisions about your Mig welder settings.

Let’s break down three fundamental terms you’ll encounter:

• Voltage: Voltage, measured in volts (V), determines the electrical potential difference between the welding electrode (wire) and the workpiece. It plays a significant role in controlling the heat generated during welding. Higher voltage settings create a hotter, more penetrating arc, while lower voltage settings produce a cooler, shallower arc.
• Amperage: Amperage, measured in amperes (A), refers to the amount of electrical current flowing through the welding circuit. It directly affects the size and strength of the weld bead. Higher amperage settings result in a larger, more robust weld, while lower amperage settings create smaller, more delicate welds.
• Wire Feed Speed: Wire feed speed, measured in inches per minute (IPM) or centimeters per minute (CPM), controls the rate at which the welding wire is fed into the arc. This setting influences the size and consistency of the weld puddle. Increasing the wire feed speed increases the rate of deposition, while decreasing it reduces the rate.

How to identify and locate these settings on your welder

Now that you’re acquainted with the terminology, let’s get practical. Finding and identifying these critical settings on your Mig welder is vital before you can start adjusting them with confidence.

• Refer to the Manual: The first step should always be consulting your Mig welder’s user manual. It’s a treasure trove of information specific to your machine. It will guide you to the location of voltage, amperage, and wire feed speed controls.
• Control Panel: Most Mig welders feature a control panel, often located on the front or top of the machine. On this panel, you’ll typically find knobs or digital displays for adjusting voltage and wire feed speed. Amperage settings may also be present here or on a separate panel.
• Wire Feeder: As the wire feeder is directly linked to wire feed speed, you’ll often find wire feed speed adjustments integrated into the wire feeder itself. Look for knobs or dials that allow you to fine-tune the wire feed speed.
• Gas Regulator and Flowmeter: If you’re using shielding gas, the gas regulator and flowmeter are usually connected to the gas cylinder. These components have clear pressure and flow rate adjustment mechanisms .

Voltage Settings

Voltage is a pivotal factor in Mig welding, influencing the heat generated by the electrical arc. Understanding its role is crucial for achieving the desired weld quality:

How to Choose the Right Voltage Setting

Selecting the correct voltage setting is a skill that develops with experience. Here’s a step-by-step process to help you make informed choices:

Real-World Examples of When to Adjust Voltage

To put voltage adjustments into perspective, here are some real-world scenarios where modifying the voltage setting can improve your welds:

Troubleshooting Common Voltage-Related Issues

While mastering voltage settings, you might encounter some common issues. Here’s how to troubleshoot and address them:

Amperage Settings

The Significance of Amperage in Mig Welding

Amperage, measured in amperes (A), is a critical parameter in Mig welding, directly impacting the size, strength, and quality of your welds. Understanding its significance is essential for achieving optimal results:

Selecting the Appropriate Amperage for Your Project

Choosing the right amperage setting is crucial for the success of your Mig welding project. Here’s a systematic approach to help you make the best selection:

Demonstrating Amperage Adjustments with Practical Scenarios

To better grasp the impact of amperage adjustments, let’s explore some practical scenarios where modifying the amperage setting can enhance your welding outcomes:

Addressing Amperage-Related Challenges and Solutions

As you gain experience in adjusting amperage settings, you may encounter common issues. Here’s a troubleshooting guide to help you resolve amperage-related challenges:

Wire Feed Speed Settings

The Importance of Wire Feed Speed for Weld Quality

Wire feed speed is a crucial parameter in Mig welding, directly influencing the quality and consistency of your welds. Understanding its importance is essential for achieving desired results:

How to Determine the Correct Wire Feed Speed

Selecting the appropriate wire feed speed is crucial for achieving optimal weld quality. Here’s a systematic approach to help you determine the correct setting:

Hands-On Examples of Adjusting Wire Feed Speed

To better understand how wire feed speed adjustments impact your welding, let’s explore some hands-on examples in various welding scenarios:

Dealing with Common Wire Feed Speed Problems

As you become more adept at adjusting wire feed speed, you may encounter some common issues. Here are solutions to address wire feed speed-related challenges:

Shielding Gas Settings

Shielding gases play a vital role in Mig welding, serving to protect the weld pool from atmospheric contamination. An introduction to these gases will help you understand their importance:

Types of Shielding Gases and Their Applications

There are various types of shielding gases available for Mig welding, each with its own set of characteristics and applications:

Guidelines for Choosing the Right Shielding Gas

Selecting the appropriate shielding gas is essential for achieving quality welds. Here are some guidelines to help you make an informed choice:

Troubleshooting Gas-Related Issues

While working with shielding gases, you may encounter some common issues. Here’s how to troubleshoot and resolve gas-related problems:

MUST READ: Do you have to use gas to weld!?

Welding Technique and Settings Interaction

Explaining the Relationship Between Settings and Welding Technique

Understanding how welding technique and settings interact is crucial for achieving precise and consistent results in Mig welding. Let’s delve into the intricacies of this relationship:

• Arc Length: The distance between the welding gun’s contact tip and the workpiece affects the arc’s stability. Longer arcs require higher voltage settings, while shorter arcs demand lower voltage settings.
• Travel Speed: The rate at which you move the welding gun along the joint influences the weld’s appearance and penetration. Slower travel speeds often require higher wire feed speed settings for proper deposition.
• Work Angle: The angle at which you hold the welding gun relative to the joint affects the heat input and penetration. A slight push angle might necessitate higher amperage settings for deeper penetration.
• Welding Position: Different positions (flat, horizontal, vertical, overhead) influence the direction of heat and molten metal. Adjust settings accordingly to maintain control and prevent weld defects.

How to Fine-Tune Settings Based on Your Welding Style

Adapting settings to your welding style is a skill that evolves with experience. Here’s how to fine-tune settings to match your technique:

• Experiment and Observe: Begin with recommended settings and gradually make small adjustments while closely observing the results. Keep notes on what works best for your style.
• Practice Welding Techniques: Practice various welding techniques such as stringer beads, weave beads, and circles to understand how settings affect each method differently.
• Learn from Others: Seek guidance from experienced welders or mentors who can provide insights into fine-tuning settings based on your specific style and project requirements.
• Stay Consistent: Consistency in your welding technique is key. Aim to replicate successful welds by maintaining a consistent approach to settings and motion.

Troubleshooting Common Mig Welder Setting Issues

Mig welding is a versatile process, but even with the right settings, issues can arise.

Understanding the potential causes is the first step in troubleshooting:

Practical Solutions for Issues Such as Spatter, Poor Penetration, and Irregular Bead Formation

Troubleshooting common Mig welding issues involves practical solutions that address both the symptoms and underlying causes:

As we wrap up our look into MIG Welder Settings, you now have the know-how to confidently navigate this essential territory.

From controlling voltage to adjusting wire feed speed and managing shielding gas flow rates, you’ve uncovered the fundamental elements for top-notch welding. These settings, sometimes seen as technical, are your tools to craft clean, strong welds.

As you embark on your welding projects armed with this newfound knowledge, remember that practice and experience are your best teachers.

Experimentation and fine-tuning will help you master your MIG welder. Whether you’re welding for structural strength, artistic expression, or industrial needs, your ability to configure your MIG welder settings will make all the difference.

So, as you stand ready for your welding journey, welder in hand, let your passion for the craft and your commitment to professionalism guide you. The world of welding is yours to explore, and your expertise in MIG Welder Settings will ensure the structures you create endure and impress.

Frequently Asked Questions

How often should i calibrate my mig welder settings.

Calibration frequency can vary depending on usage, but a monthly calibration check is a good starting point. Regularly inspect your welder, and if you notice inconsistencies in your welds, perform calibration checks as needed.

What should I do if I encounter excessive spatter during welding?

To reduce spatter, slightly lower your wire feed speed and adjust voltage and amperage settings for a smoother arc. Additionally, ensure your work surface is clean, and replace worn contact tips or liners if necessary.

What can I do to improve poor penetration in my welds?

If you’re experiencing poor penetration, increase the amperage setting for more heat and penetration depth. Adjust the wire feed speed to provide sufficient filler metal, maintain a consistent travel speed and angle, and ensure proper joint preparation and material cleanliness.

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The Ultimate Guide to MIG Welding: Tips and Techniques for Success

MIG welding stands as a cornerstone in metalworking, playing a pivotal role in various industries and applications. Its versatility and efficiency make it indispensable in automotive, construction, fabrication, and manufacturing sectors, among others. With its ability to weld a wide range of metals, including steel, aluminum, and stainless steel, MIG welding offers unparalleled convenience and adaptability for projects of all sizes. Whether it's assembling structural components, crafting intricate designs, or repairing metalwork, MIG welding provides a reliable and cost-effective solution, making it an essential technique in the modern welding arsenal.

Now, let's delve into a crucial tip for achieving success in MIG welding: maintaining the correct electrode extension. The electrode extension, also known as stick-out, refers to the distance between the contact tip of the welding gun and the workpiece surface. Ensuring the appropriate electrode extension is essential for achieving optimal weld quality and preventing common issues like erratic arcs, spatter, and lack of fusion. Typically, maintaining a consistent electrode extension of around ¼ to ⅜ inch (6 to 10 mm) is recommended for most MIG welding applications. However, adjusting the stick-out based on factors such as welding position, material thickness, and joint configuration is crucial for achieving desired results. By carefully controlling the electrode extension, welders can enhance arc stability, improve bead appearance, and ensure proper penetration, ultimately leading to high-quality welds. Remember, attention to detail in electrode extension can significantly elevate your MIG welding performance and the overall integrity of your welds.

Whether you're a beginner looking to dive into the world of MIG welding or a seasoned welder aiming to enhance your skills, this comprehensive guide is your roadmap to mastering the art of Metal Inert Gas (MIG) welding. From  understanding the basics of MIG welding equipment to refining your  welding techniques for flawless results, this guide covers everything you need to know to become a proficient MIG welder. So, grab your welding helmet and let's embark on a journey to unlock the secrets of successful MIG welding!

Understanding MIG Welding Equipment 

MIG welding is a type of arc welding that uses a continuous wire electrode and an inert gas to create a weld pool and join metal pieces. MIG welding is also known as Gas Metal Arc Welding (GMAW) or Metal Inert Gas (MIG) Welding. To perform MIG welding, you need the following equipment:

• Welding Machine: 

MIG welding machines, also known as MIG welders or power sources, are the backbone of any MIG welding setup. These machines generate the electrical current needed for the welding process. When choosing a welding machine, consider factors such as power output, duty cycle, and voltage settings. Higher-end models often offer more advanced features, providing greater control and versatility for different welding tasks.The welding machine can be either AC or DC, depending on the type of wire and metal you are using. The welding machine also controls the voltage, amperage, and wire feed speed of the welding circuit.

• Wire Feeder: 

This is the device that feeds the wire electrode from a spool to the welding gun or into the welding puddle. The wire feeder can be either integrated with the welding machine or separate. It plays a pivotal role in maintaining a stable arc and achieving consistent welds. Wire feeders come in various types, including push-pull systems for aluminum welding and dual-drive feeders for enhanced precision. Understanding the wire feeder's settings and adjustments is essential for achieving optimal welding results.

• Shielding Gas: 

Shielding gas is a key element in MIG welding, serving to protect the welding pool from atmospheric contaminants like oxygen and nitrogen. Common shielding gases include argon, carbon dioxide, and mixtures of the two. The choice of shielding gas depends on the material being welded and the specific welding requirements. Proper gas selection and regulation contribute significantly to the overall weld quality, minimizing defects and ensuring a clean weld bead.

• Welding Gun: 

The welding gun, or MIG torch, is the handheld tool that you hold and manipulate to create the weld. It typically consists of a trigger for wire control, a nozzle for gas flow, and a contact tip that transfers electrical current to the wire. Understanding the anatomy of the welding gun is essential for precise control and manipulation during the welding process. Different guns may have features like ergonomic designs and interchangeable components for customization.

• Consumables: 

These are the parts of the welding equipment that wear out or need to be replaced regularly. The consumables for MIG welding include the wire electrode, the contact tip, the nozzle, and the gas cylinder. The wire electrode is the filler metal that melts and joins the base metal. The contact tip and the nozzle are subject to heat and spatter and need to be cleaned or changed frequently. The gas cylinder contains the shielding gas and needs to be refilled or replaced when empty.

Safety Precautions and Personal Protective Equipment (PPE)

MIG welding is a versatile and efficient process, but it also involves some potential hazards that require proper safety precautions and personal protective equipment (PPE) to avoid. In this section, we will cover the main aspects of welding safety gear, ventilation and fume extraction, as well as fire safety measures that you should follow to ensure a safe and successful MIG welding operation.

A. Welding Safety Gear

The first line of defense against the dangers of MIG welding is wearing appropriate welding safety gear that protects your eyes, ears, skin, and respiratory system from the harmful effects of heat, sparks, spatter, electric shock, and fumes. Some of the essential welding safety gear items are:

1. Welding Helmet:

The welding helmet is a crucial piece of safety gear, providing protection against intense light, sparks, and debris. Auto-darkening helmets are highly recommended, as they automatically adjust the shading of the lens in response to the welding arc, ensuring the welder's eyes are shielded from harmful UV and infrared radiation.

2. Protective Clothing:

Welders should wear flame-resistant clothing, such as welding jackets, pants, and gloves, to safeguard against burns and sparks. The clothing should cover exposed skin to minimize the risk of injury from UV radiation and hot metal.

3. Footwear:

Sturdy, closed-toe leather boots with high ankle support protect the feet from falling objects and potential hazards in the welding environment. Steel-toed boots offer an additional layer of protection.

4. Ear Protection:

Welding operations can be noisy, especially in industrial settings. Ear protection, such as earmuffs or earplugs, is essential to prevent hearing damage from prolonged exposure to high levels of noise.

B. Ventilation and Fume Extraction

Another crucial aspect of MIG welding safety is ensuring adequate ventilation and fume extraction in your work area. MIG welding produces a lot of fumes and gases that can be harmful to your health if inhaled in large quantities or for prolonged periods. Some of the common substances found in welding fumes and gases are Ozone, Nitrogen oxides, Carbon monoxide, and Metal fumes:

To prevent or reduce your exposure to welding fumes and gases, you should follow these ventilation and fume extraction guidelines:

• Use general ventilation: General ventilation is the use of fans, blowers, or natural air movement to dilute and disperse the welding fumes and gases in the work area. General ventilation is suitable for outdoor or large indoor spaces, where the welding is not continuous or intensive, and where the fumes and gases are not highly toxic. You should ensure that the ventilation system is working properly, and that the air flow is directed away from your breathing zone and other workers.
• Use local exhaust ventilation: Local exhaust ventilation is the use of hoods, ducts, or filters to capture and remove the welding fumes and gases at or near the source. Local exhaust ventilation is more effective and efficient than general ventilation, as it prevents the fumes and gases from spreading in the work area and reaching your breathing zone.
• Use respiratory protective equipment: Respiratory protective equipment is the use of masks, respirators, or air-supplied helmets to filter or supply clean air to your lungs. Respiratory protective equipment is the last resort and the least preferred option for controlling your exposure to welding fumes and gases, as it does not eliminate the source of the hazard, and it depends on your compliance and comfort.

C. Fire Safety Measures

The third and final aspect of MIG welding safety is taking fire safety measures to prevent and control any fires or explosions that may occur during or after the welding process. MIG welding involves high temperatures, sparks, and spatter that can ignite flammable or combustible materials in the vicinity of the welding area. Some safety measures are:

Fire Extinguishers:

• Have fire extinguishers readily available in the welding area, rated for use on both electrical and metal fires. Regularly inspect and maintain extinguishers to ensure they are in working order.

Clearing Combustibles:

• Keep the welding area free of flammable materials and substances. Clear the workspace of any debris, paper, or other combustible items that could pose a fire hazard.

Emergency Procedures:

• Ensure all welders are familiar with emergency procedures, including evacuation routes and the location of emergency exits. Conduct regular drills to reinforce safety protocols and response actions in the event of a fire or other emergencies.

Setting Up Your MIG Welder 

Before you can start MIG welding, you need to set up your MIG welder properly. This involves choosing the right wire and gas, selecting the proper voltage and wire feed speed, adjusting the gas flow rate, and installing and configuring the consumables. In this section, we will guide you through the steps and tips for setting up your MIG welder.

A. Choosing the Right Wire and Gas

The wire and gas are two of the most important factors that affect the quality and appearance of your MIG welds. The wire is the filler metal that is fed through the MIG gun and melted by the arc to join the base metals. The gas is the shielding gas that is supplied through the MIG gun and protects the arc and the weld pool from the atmospheric contamination. You need to choose the right wire and gas for the type and thickness of the metal you are welding, as well as the position and technique of the welding.

There are two main types of wire for MIG welding: solid wire and flux-cored wire. Solid wire is a solid metal wire that requires a shielding gas to weld. Flux-cored wire is a tubular wire that contains a flux inside that generates its own shielding gas when burned by the arc. Solid wire is more suitable for welding thin metals, clean metals, and in all positions. Flux-cored wire is more suitable for welding thick metals, dirty metals, and in flat and horizontal positions.

There are three main types of gas for MIG welding: inert gas, active gas, and mixed gas. Inert gas is a gas that does not react with the metal or the arc, such as argon or helium. Active gas is a gas that reacts with the metal or the arc, such as carbon dioxide or oxygen. Mixed gas is a combination of inert and active gases, such as argon and carbon dioxide, or argon and oxygen. Inert gas is more suitable for welding non-ferrous metals, such as aluminum or copper. Active gas is more suitable for welding ferrous metals, such as steel or iron. Mixed gas is more suitable for welding a variety of metals, as it provides a balance between penetration and stability.

To choose the right wire and gas for your MIG welder, you need to consider the following factors:

• The type and thickness of the metal you are welding
• The position and technique of the welding
• The penetration and deposition rate of the weld
• The strength and corrosion resistance of the weld
• The coverage and protection of the weld
• The spatter and appearance of the weld

B. Selecting Proper Voltage and Wire Feed Speed

The voltage and wire feed speed are two of the most important settings that affect the performance and the outcome of your MIG welds. The voltage is the electrical potential that is applied across the arc and determines the heat and the width of the weld. The wire feed speed is the rate at which the wire is fed through the MIG gun and determines the amount and the length of the weld. You need to select the proper voltage and wire feed speed for the type and size of the wire you are using, as well as the thickness and the joint type of the metal you are welding.

There are two main ways to adjust the voltage and wire feed speed on your MIG welder: manual and automatic. Manual adjustment is when you manually set the voltage and wire feed speed on the control panel of your MIG welder, based on your experience, preference, or trial and error. Automatic adjustment is when you use a feature or a device that automatically adjusts the voltage and wire feed speed for you, based on the feedback from the arc, the wire, or the metal. Manual adjustment is more suitable for experienced welders, who have a good sense of the optimal settings for different situations. Automatic adjustment is more suitable for beginner welders, who need more guidance and convenience for setting up their MIG welder.

There are also different modes and methods of automatic adjustment for the voltage and wire feed speed on your MIG welder, depending on the type and model of your MIG welder. Some of the common modes and methods of automatic adjustment are:

• Synergic mode: Synergic mode is a feature that automatically adjusts the voltage and wire feed speed in sync with each other, based on the feedback from the arc. Synergic mode allows you to set only one parameter, such as the wire diameter, the metal thickness, or the desired arc length, and the MIG welder will automatically adjust the other parameters for you, to achieve a stable and consistent arc.
• Voltage sensing mode: Voltage sensing mode is a feature that automatically adjusts the wire feed speed in proportion to the voltage, based on the feedback from the wire. Voltage sensing mode allows you to set the voltage manually, and the MIG welder will automatically adjust the wire feed speed for you, to maintain a constant arc length and a smooth wire feeding.
• Spool gun: Spool gun is a device that automatically adjusts the wire feed speed in relation to the distance between the spool and the MIG gun, based on the feedback from the wire. Spool gun allows you to use a smaller and lighter spool of wire that is attached to the MIG gun, instead of a larger and heavier spool of wire that is attached to the MIG welder. Spool gun is especially useful for welding aluminum, as it prevents the wire from getting tangled or jammed in the long cable.

To select the proper voltage and wire feed speed for your MIG welder, you need to consider the following factors:

• The type and size of the wire you are using
• The thickness and joint type of the metal you are welding
• The heat and width of the weld
• The amount and length of the weld
• The stability and consistency of the arc
• The smoothness and speed of the wire feeding

C. Adjusting Gas Flow Rate

The gas flow rate is another important setting that affects the quality and the appearance of your MIG welds. The gas flow rate is the amount of gas that is supplied through the MIG gun and covers the arc and the weld pool. You need to adjust the gas flow rate for the type and percentage of the gas you are using, as well as the size and length of the MIG gun and the cable, and the environmental conditions of the welding area.

The gas flow rate is measured in cubic feet per hour (cfh) and is controlled by a regulator or a flowmeter that is attached to the gas cylinder. The regulator or the flowmeter has a gauge that indicates the gas pressure and a knob that adjusts the gas flow rate. You need to set the gas pressure and the gas flow rate according to the specifications of your MIG welder and your welding process.

The gas flow rate affects the coverage and the protection of the weld, as well as the spatter and the appearance of the weld. If the gas flow rate is too low, the weld will not be adequately shielded from the atmospheric contamination, and the weld will be porous, weak, and discolored. If the gas flow rate is too high, the weld will be exposed to excessive turbulence and cooling, and the weld will be spattered, distorted, and oxidized. You need to find the optimal gas flow rate that provides sufficient shielding without causing any adverse effects.

To adjust the gas flow rate for your MIG welder, you need to consider the following factors:

• The type and percentage of the gas you are using
• The size and length of the MIG gun and the cable
• The environmental conditions of the welding area

D. Installing and Configuring Consumables

The consumables are the parts of the MIG gun that are in direct contact with the arc and the weld pool, and that wear out or need to be replaced over time. The consumables include the contact tip, the nozzle, the gas diffuser, and the liner. You need to install and configure the consumables properly for the type and size of the wire you are using, as well as the type and percentage of the gas you are using.

The consumables affect the transfer and the delivery of the current and the gas to the weld, as well as the performance and the durability of the MIG gun. If the consumables are not installed and configured properly, the weld will be affected by poor arc stability, erratic wire feeding, excessive spatter, and reduced shielding. You need to check and maintain the consumables regularly, and replace them when they are damaged, worn, or contaminated.

To install and configure the consumables for your MIG welder, you need to consider the following factors:

• The transfer and delivery of the current and the gas to the weld
• The performance and durability of the MIG gun
• The arc stability and wire feeding of the weld
• The spatter and shielding of the weld

MIG Welding Techniques 

A. joint preparation and fit-up.

Before you start welding, you need to prepare the joint and make sure the pieces fit together properly. This will ensure a strong and consistent weld. Here are some tips for joint preparation and fit-up:

• Clean the base metal and remove any dirt, oil, paint, rust or other contaminants that could affect the weld quality.
• Use a wire brush, grinder, sandpaper or other tools to create a smooth and uniform surface on the base metal.
• Choose the appropriate filler wire for the base metal and the weld position. For example, if you are welding steel, you can use ER70S-6 wire, which is suitable for most applications.
• Cut the filler wire to the desired length and straighten it if necessary.
• Align the pieces to be welded and clamp them securely in place. Make sure there are no gaps or misalignments between the pieces.
• If needed, use a backing strip or a backing gas to prevent burn-through or oxidation on the back side of the weld.

B. Correct Welding Positions

The welding position refers to the orientation of the weld joint relative to the horizontal and vertical planes. There are four basic welding positions: flat, horizontal, vertical and overhead. Each position has its own challenges and requires different techniques to achieve a good weld. Here are some general guidelines for correct welding positions:

• Flat position: This is the easiest position to weld, as the weld pool is supported by gravity and the arc is stable. Hold the gun at a 90-degree angle to the workpiece and move it steadily along the joint. You can use either a forehand or a backhand technique, depending on the direction of travel.
• Horizontal position: This position is more difficult than the flat position, as the weld pool tends to sag and the arc is less stable. Hold the gun at a 15-degree angle to the workpiece and move it slightly upward along the joint. Use a forehand technique to prevent the weld pool from falling.
• Vertical position: This position is the most difficult to weld, as the weld pool is affected by gravity and the arc is unstable. Hold the gun at a 5- to 15-degree angle to the workpiece and move it either upward or downward along the joint. Use a backhand technique for upward welding and a forehand technique for downward welding. You may also need to use a weaving or a stepping motion to control the weld pool.
• Overhead position: This position is similar to the vertical position, but inverted. Hold the gun at a 5- to 15-degree angle to the workpiece and move it either forward or backward along the joint. Use a backhand technique for forward welding and a forehand technique for backward welding. You may also need to use a weaving or a stepping motion to control the weld pool.

C. Travel Speed and Angle

The travel speed and angle are two important factors that affect the weld quality and appearance. The travel speed is the rate at which you move the gun along the joint, and the angle is the direction of the gun relative to the joint. Here are some tips for adjusting the travel speed and angle:

• Travel speed: The travel speed should match the wire feed speed and the heat input 4 . If the travel speed is too fast, the weld will be narrow, shallow and weak. If the travel speed is too slow, the weld will be wide, deep and prone to defects. A good way to determine the optimal travel speed is to listen to the sound of the arc. It should be steady and crackling, not hissing or popping.
• Angle: The angle of the gun should be between 5 and 15 degrees from the perpendicular to the joint. If the angle is too large, the weld will be uneven and distorted. If the angle is too small, the weld will be shallow and lack penetration. A good way to maintain the correct angle is to keep the gun nozzle about 1/4 to 3/8 inch away from the workpiece.

D. Electrode Extension

The electrode extension, also known as the stick-out, is the length of the wire that extends beyond the contact tip of the gun. The electrode extension affects the arc voltage, the heat input and the weld penetration. Here are some tips for adjusting the electrode extension:

• Electrode extension: The electrode extension should be between 1/4 and 1/2 inch for most applications. If the electrode extension is too long, the arc voltage will increase, the heat input will decrease and the weld penetration will decrease. If the electrode extension is too short, the arc voltage will decrease, the heat input will increase and the weld penetration will increase. A good way to measure the electrode extension is to use a ruler or a gauge.
• Contact tip: The contact tip is the part of the gun that transfers the current to the wire. The contact tip should be clean and free of spatter, and match the diameter of the wire. If the contact tip is dirty, worn or mismatched, the wire feed will be erratic and the arc will be unstable.

E. Techniques for Different Materials (Steel, Aluminum, Stainless Steel)

MIG welding can be used to weld different materials, such as steel, aluminum and stainless steel. However, each material has its own characteristics and challenges that require different techniques and settings. Here are some tips for welding different materials:

• Steel: Steel is the most common material for MIG welding, as it is strong, durable and easy to weld. However, steel can also rust, warp and crack if not welded properly. To weld steel, you need to use a shielding gas that contains carbon dioxide, such as 75% argon and 25% CO2. You also need to use a filler wire that matches the strength and composition of the base metal, such as ER70S-6.
• Aluminum: Aluminum is a lightweight and corrosion-resistant material that is widely used in various industries. However, aluminum is also soft, sticky and prone to oxidation if not welded properly. To weld aluminum, you need to use a shielding gas that contains argon, such as 100% argon or 75% argon and 25% helium. You also need to use a filler wire that matches the alloy and temper of the base metal, such as ER4043 or ER5356.
• Stainless steel: Stainless steel is a high-quality and corrosion-resistant material that is used for various applications. However, stainless steel is also hard, brittle and sensitive to heat if not welded properly. To weld stainless steel, you need to use a shielding gas that contains argon and carbon dioxide, such as 98% argon and 2% CO2. You also need to use a filler wire that matches the grade and composition of the base metal, such as ER308L or ER316L.

Tips for Improving Weld Quality 

1 . maintaining consistent electrode extension.

One of the simplest ways to improve weld quality is to maintain a consistent electrode extension throughout the weld. As mentioned earlier, the electrode extension affects the arc voltage, the heat input and the weld penetration. If the electrode extension varies during the weld, the weld quality will suffer. Here are some tips for maintaining consistent electrode extension:

• Use a ruler or a gauge to measure the electrode extension before starting the weld.
• Keep the gun nozzle about 1/4 to 3/8 inch away from the workpiece.
• Avoid touching the workpiece with the wire or the nozzle, as this will shorten the electrode extension and cause spatter.
• Avoid pulling or pushing the wire, as this will change the electrode extension and cause wire feed problems.

2 . Monitoring Welding Parameters

Another way to improve weld quality is to monitor the welding parameters, such as the voltage, the current, the wire feed speed and the gas flow rate. These parameters affect the arc characteristics, the weld pool behavior and the weld appearance. If the welding parameters are not set correctly or change during the weld, the weld quality will suffer. Here are some tips for monitoring welding parameters:

• Use a digital display or a meter to check the welding parameters before starting the weld.
• Adjust the welding parameters according to the material, the thickness, the joint type and the position.
• Use a consistent travel speed and angle to maintain a stable arc and a uniform weld bead.
• Listen to the sound of the arc and watch the weld pool to detect any changes in the welding parameters.

3. Cleaning and Preparing Base Metal

A third way to improve weld quality is to clean and prepare the base metal before welding. As mentioned earlier, the base metal should be free of any dirt, oil, paint, rust or other contaminants that could affect the weld quality. If the base metal is not clean and prepared, the weld will be weak, porous and discolored. Here are some tips for cleaning and preparing base metal:

• Use a wire brush, grinder, sandpaper or other tools to remove any surface contaminants from the base metal.
• Solvents, such as acetone, can be used to wipe off any residual grease or oil from the base metal.
• Use a stainless steel brush to clean aluminum or stainless steel, as these materials are prone to oxidation.

Advanced MIG Welding Techniques 

A. pulse welding.

Pulse welding is a technique that uses a power source that alternates between a high peak current and a low background current. This creates a pulsating arc that melts the metal and then cools it rapidly, resulting in a finer and more uniform weld bead. Pulse welding has several advantages, such as:

• Reducing heat input and distortion
• Improving weld penetration and fusion
• Enhancing weld appearance and quality
• Enabling welding of thin and thick materials
• Reducing spatter and fumes

Applications:

• Aerospace and automotive industries where precise control and minimal distortion are crucial.
• Welding thin materials like sheet metal or aluminum.

B. Dual Shielding

Dual shielding is a technique that uses two types of shielding gases: an active gas and an inert gas. The active gas, such as carbon dioxide or oxygen, reacts with the molten metal and creates a slag layer that protects the weld from oxidation and contamination. The inert gas, such as argon or helium, stabilizes the arc and improves the weld pool fluidity. Dual shielding has several advantages, such as:

• Increasing weld deposition rate and productivity
• Improving weld strength and toughness
• Enhancing weld penetration and fusion
• Reducing porosity and cracking
• Enabling welding of dirty or rusty materials

C. Multi-Pass Welding

Multi-pass welding is a technique that involves making several passes or layers of weld beads over the same joint. This is done to fill a large gap, to join thick materials, or to improve the weld quality and appearance. Multi-pass welding has several advantages, such as:

• Increasing weld penetration and fusion
• Reducing distortion and stress
• Enabling welding of complex joints and shapes
• Construction of pressure vessels.
• Welding of heavy structural components.

D. Vertical and Overhead Welding

Vertical and overhead welding are techniques that involve welding in positions other than flat and horizontal. These positions are more challenging and require more skill and experience, as the weld pool is affected by gravity and the arc is less stable. Vertical and overhead welding have several advantages, such as:

• Saving time and material
• Improving weld accessibility and visibility
• Enabling welding of various joints and shapes
• Vertical welding is common in structural applications.
• Overhead welding is often used in projects where welding must be performed on the upper side of joints, such as welding pipes to overhead structures.

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MIG welding is a versatile and popular welding process that can be used for various applications and materials. However, mastering MIG welding requires a comprehensive understanding of equipment, safety measures, and various techniques. Throughout this guide, we've highlighted key points such as the importance of proper setup, safety precautions, and fundamental and advanced welding techniques. Consistent electrode extension, meticulous parameter control, and thorough base metal preparation are paramount for achieving high-quality welds.

As you embark on your MIG welding journey, remember that learning and refining your skills is a continuous process. Embrace opportunities for hands-on practice, experiment with different materials, and stay informed about advancements in welding technology. By doing so, you'll not only enhance your skills but also unlock the potential to tackle a diverse range of welding projects with confidence.

We hope this article has helped you to improve your MIG welding skills and knowledge. However, remember that the best way to learn and refine your welding technique is to practice and seek feedback. Therefore, we encourage you to continue learning and reach out to us for more information and enquiries at tikweld.com

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MIG welder settings explained – Amperage & Wire Speed

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MIG welding process is one of the most straightforward processes to master, but beginners often have issues getting the settings right. You can purchase the most expensive MIG welding machine on the market, but the results may still vary.

To help you dial in your machine, we will thoroughly explain each set’s representation. Keep in mind that there are some universal rules, but most differ from a device.

However, by understanding the basics we explained in the article, you will be able to diagnose the issue.

First Things First – Material Choice and Thickness

Before you start banging your head with MIG welder settings, you should first ask yourself – What and how thick material will you be welding? 

Each material type has its unique mechanical properties.

For example, different metal alloys have different melting temperatures, tensile strength, and hold that heat differently. Therefore, there are no universal settings applicable to all material types. 

Mild steel is the most common metal, and as a hobbyist, it is most likely you will deal with it. The 0.25% carbon content is lower than medium and high carbon steels, which makes it a highly machinable metal.

On the other hand, seasoned welders might occasionally weld aluminum or work with stainless steel. Aluminum has many positive characteristics like being non-corrosive, lightweight, and is visually appealing. Unfortunately, all the positive sides of aluminum are what make it difficult for fabrication.

So before you start welding, you should consider the material you will be welding and its thickness.

How Does Material Thickness Affect MIG Welder Settings(Metal Inert Gas Welding)?

The thickness of the material might be one of the crucial things you should consider when setting up your machine.

When welding Stick or TIG, you can use nearly similar settings with different thicknesses, but with MIG, it gets tricky.

The general rule, also known as the thumb rule, states you should use  1 amp for .001 inch of material thickness . So, for example, if you are welding 1/8″ mild steel (0.125 inches thick), you should provide 125 amps.

However, this rule applies to mild steel, while you will have to provide about 10-15% less current for stainless steel or 25% more current for aluminum.

In addition, there are a couple of flaws when it comes to thicker metals. So, when dealing with 1/2″ thick metals, you should provide 500 amps while following the rule. However, some manufacturers claim you can use their machines rated at 200-250 amps to do it, while the recommendation says otherwise.

Therefore, you should use the rule as a guideline for optimal performance and follow the manufacturer’s recommendations.

Shielding Gas and MIG Welding Wire

Shielding gas plays a crucial role in protecting your weld bead from defects. So before you start your welding, you will have to choose a mixture of inert gases according to a type of metal and adjust the flow according to welding conditions.

In MIG welding, you will be mostly using Argon, Helium, CO2, or a touch of Oxygen. In addition, the wire types (filler material) should suit the base metal, and here are some recommendations.

• If you are welding mild steel (carbon steel), the best choices are C25 gas type (75% Argon and 25% Carbon Dioxide) and ER70s electrode.
• As for stainless steel, C2 gas (98% Argon and 2% Carbon Dioxide) and ER308L wire type are your choices.
• Aluminum is tricky, as you will have to provide ER4043 wire with 100% Argon gas.

A high percentage of Argon or Helium added to a mix creates a hotter arc in the weld area. Besides choosing the proper type of wire, you should use an adequate filler thickness. Select one for your most commonly used thicknesses since you don’t want to change the wire.

• 30-130 amps: .023 inch
• 40-145 amps: .030 inch
• 50-180 amps: .035 inch
• 75-250 amps: .045 inch

Weld Preparation

Welding preparation is no mystery as the clean welding surfaces will produce clean welds. Welder settings may differ if you work with oily, rusty, or dirty steel, so you want to ensure a clean weld.

In addition, dirty joints spatter a lot! So if you fail to clean a joint, excessive spatter may burn you or cause a fire. Settings don’t create good welds; they make good welds possible. But only if you do the rest.

That’s why you should always clean, de-scale, grind and degrease the work material before you start welding.

MIG Welding Settings: What Do They Mean?

After you have determined the thickness and type of material, selected a proper shielding gas and electrode, and cleaned the surface, it is time to set up your machine. This section will examine the voltage and wire speed and shielding gas flow.

MIG Welding Voltage Setting

MIG welding almost always uses a DC+ polarity type. The most straightforward explanation states that the voltage determines the height and width of the bead. In addition, there is a relationship between arc voltage and arc length. 

A short arc (low voltage settings) yields a narrow, ropey bead with a possibility of poor arc starts. A longer arc (more voltage) produces a flatter, wider bead.

Too much arc length makes a very flat bead and the undercut possibility.

To get the voltage straight, you should follow the manufacturer’s recommendations. For example, instruction manual or side door charts usually feature only guidelines.  

However, if there are no recommendations whatsoever (which is rare today), you should practice independently. Use a piece of scrap metal that is thick as the part you will weld, and start experimenting. Slowly turn the values up or down, until you get decent results.

You can use a sound to determine the proper voltage. Adjust the voltage until you get a nice bacon frying sound. Too little voltage and it will snub and sound like a drive-by. Too much voltage and the wire will try to burn back, or you’ll get the sound of a rattle or hiss. 

Wire Feed Speed

Wire-speed controls amperage, as well as the amount of weld penetration. If you turn the wire speed up, you might have to deal with a burn-through. On the contrary, a narrow, often convex bead with poor tie-in at the toes will occur if the feed is too slow due to insufficient penetration.

Some experienced welders like to adjust wire feed speed to their preferences for different transfer type (e.g., short circuit transfer).

The instruction manual and side door chat should give you recommendations for each material thickness. If there are no guidelines, you can use our chart to serve as a starting point. For example, for .030-inch wire, multiply by 2 inches per amp, while for .023, multiply it 3.5 times.

For wire size multiply by Ex. using 1/8 inch (125 amps)

Gas Flow Settings

Once you set up your machine to produce fine weld quality, you should set the shielding gas flow to protect it from defects. The primary purpose of the gases and mixtures we described above is to prevent contamination of your weld. Gas flow is measured in cubic feet per minute CFM.

As for the other settings, you should experiment since the amount of flow depends on current welding conditions. For example, if you are welding in the shop or other indoor conditions, 15-20 CFM will do just fine.

However, if you open the door or a draft present, you should turn it up to 35-40 CFM. But, keep in mind that too much gas pressure can cause turbulence and suck in air to contaminate the weld.

MIG Welding Charts

The welding chart that comes with your machine undoubtedly provides the best guidelines for the welding start. However, state-of-the-art hobbyist MIG welders such as Miller Millermatic or YesWelder MIG 205 DS feature intelligent settings.

With synergic or auto-set settings, you have to input the material thickness and MIG wire diameter, and the machine will do the rest. Auto-set is an excellent feature for beginners, so if you are tired of trying to figure out the machine settings, you should look for a MIG welder that provides it.

However, nothing beats the manual settings, as recommendations might be too hot or cold. That’s why you should always use charts and synergic settings as a guideline.

Wrapping Things Up:

First, you should consider the material type and thickness and adjust the accessories and equipment. Then you will have to clean your weld. Finally, voltage, wire speed, and gas flow settings come at last, where you combine everything you learned in this article.

To keep it as simple as possible, we pointed up many times that there are no universal settings that you can use on welding machines. So even though it might sound disappointing, understanding the controls is crucial.

Remember that setting the machine is a trial and error process. You will burn through the metal with too much heat, burn your MIG gun nozzle, or achieve poor penetration until you get it right.

If your hobby is turning into a passion, you can always consider one of the welding technician programs.

• MIG welder settings by Miller Electric https://www.millerwelds.com/resources/article-library/miggmaw-101-setting-the-correct-parameters
• Adjusting power settings by MIG welding UK https://www.mig-welding.co.uk/power-settings.htm
• MIG welder considiration by Tulsa Welding School https://www.tws.edu/blog/welding/mig-welder-setup-considerations/
• Tips for settings MIG parameters by Hobart Brothers https://www.hobartbrothers.com/2021/09/tips-for-setting-mig-welding-parameters-for-thin-materials/
• Welding parameters by ESAB https://www.esabna.com/euweb/mig_handbook/592mig7_1.htm

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Home / Amperage Blog / MIG Welding Basics: Techniques and Tips for Success

MIG Welding Basics: Techniques and Tips for Success

It’s important for new welding operators to establish proper MIG techniques in order to achieve good weld quality and maximize productivity. Safety best practices are key, too. It’s just as important, however, for experienced welding operators to remember the fundamentals in order to avoid picking up habits that could negatively impact welding performance.

From employing safe ergonomics to using the proper MIG gun angle and welding travel speeds and more, good MIG welding techniques provide good results. Here are some tips.

Proper ergonomics

A comfortable welding operator is a safer one. Proper ergonomics should be among the first fundamentals to establish in the MIG welding process (along with proper personal protective equipment, of course). Ergonomics  can be defined, simply, as the “study of how equipment can be arranged so that people can do work or other activities more efficiently and comfortably.” 1 The importance of ergonomics for a welding operator can have far reaching effects. A workplace environment or task that causes a welding operator to repetitively reach, move, grip or twist in an unnatural way, and even staying in a static posture for an extended period of time without rest. All can lead to repetitive stress injuries with life-long impacts.

Proper ergonomics can protect welding operators from injury while also improving productivity and profitability of a welding operation by reducing employee absences.

Some ergonomic solutions that can improve safety and productivity include:

1. Using a MIG welding gun with a locking trigger to prevent “trigger finger”. This is caused by applying pressure to a trigger for an extended period of time.

2. Using a MIG gun with a rotatable neck to help the welding operator move more easily to reach a joint with less strain on the body.

3. Keeping hands at elbow height or slightly below while welding.

4. Positioning work between the welding operator’s waist and shoulders to ensure welding is being completed in as close of a neutral posture as possible.

5. Reducing the stress of repetitive motions by using MIG guns with rear swivels on the power cable.

6. Using different combinations of handle angles, neck angles and neck lengths to keep the welding operator’s wrist in a neutral position.

Proper work angle, travel angle and movement

The proper welding gun or work angle, travel angle and MIG welding  technique depends on the thickness of the base metal and the welding position. Work angle is “the relationship between the axis of the electrode to the welders work piece”. Travel angle refers to employing either a push angle (pointing in the direction of travel) or a drag angle, when the electrode is pointed opposite of travel. (AWS Welding HandBook 9th Edition Vol 2 Page 184) 2 .

Flat position

When welding a butt joint (a 180-degree joint), the welding operator should hold the MIG welding gun at a 90-degree work angle (in relation to the work piece). Depending on the thickness of the base material, push the gun at a torch angle between 5 and 15 degrees. If the joint requires multiple passes, a slight side-to-side motion, holding at the toes of the weld, can help fill the joint and minimize the risk of undercutting.

For T-joints, hold the gun at a work angle of 45 degrees and for lap joints a work angle around 60 degrees is appropriate (15 degrees up from 45 degrees).

Horizontal position

In the horizontal welding position, a work angle of 30 to 60 degrees works well, depending on the type and size of the joint. The goal is to prevent the filler metal from sagging or rolling over on the bottom side of the weld joint.

Vertical position

For a T-joint, the welding operator should use a work angle of slightly greater than 90 degrees to the joint. Note, when welding in the vertical position, there are two methods: weld in an uphill or a downhill direction.

The uphill direction is used for thicker material when greater penetration is needed. A good technique for a T-Joint is call the upside-down V. This technique assures the welding operator maintains consistency and penetration in the root of the weld, which is where the two pieces meet. This area is the most important part of the weld.The other technique is downhill welding. This is popular in the pipe industry for open root welding and when welding thin gauge materials.

Overhead position

The goal when MIG welding overhead is to keep the molten weld metal in the joint. That requires faster travel speeds and work angles will be dictated by the location of the joint. Maintain a 5 to 15 degree travel angle. Any weaving technique should be kept to a minimum to keep the bead small. To gain the most success, the welding operator should be in comfortable position in relation to both the work angle and the direction of travel.

Wire stickout and contact-tip-to-work distance

Wire stickout will change depending on the welding process. For short-circuit welding, it is good to maintain a 1/4- to 3/8-inch wire stickout to reduce spatter. Any longer of a stickout will increase electrical resistance, lowering the current and leading to spatter. When using a spray arc transfer, the stickout should be around 3/4 inch.

Proper contact-tip-to-work distance (CTWD) is also important to gaining good welding performance. The CTWD used depends on the welding process. For example, when using a spray transfer mode, if the CTWD is too short, it can cause burnbacks. If it’s too long, it could cause weld discontinuities due to lack of proper shielding gas coverage. For spray transfer welding, a 3/4-inch CTWD is appropriate, while 3/8 to 1/2 inch would work for short circuit welding.

Welding travel speed

The travel speed influences the shape and quality of a weld bead to a significant degree. Welding operators will need to determine the correct welding travel speed by judging the weld pool size in relation to the joint thickness.

With a welding travel speed that’s too fast, welding operators will end up with a narrow, convex bead with inadequate tie-in at the toes of the weld. Insufficient penetration, distortion and an inconsistent weld bead are caused by traveling too fast. Traveling too slow can introduce too much heat into the weld, resulting in an excessively wide weld bead. On thinner material, it may also cause burn through.

Final thoughts

When it comes to improving safety and productivity, it’s up to the experienced veteran welding operator as much as the new welding to establish and follow proper MIG technique right. Doing so helps avoid potential injury and unnecessary downtime for reworking poor quality welds. Keep in mind that it never hurts for welding operators to refresh their knowledge about MIG welding and it’s in their and the company’s best interest to continue following best practices.

1. Collins Dictionary, “ergonomics,” collinsdictionary.com/dictionary/english/ergonomics. 2. Welding Handbook , 9th ed., Vol. 2, Welding Processes, Part 1. American Welding Society: Miami, Fla., p. 184. 

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MIG Welding Wire Speed + Voltage Chart

Written By: Liam Bryant

Reviewed By: Russell Egan

As an Amazon Associate I earn from qualifying purchases.

A MIG welding wire speed chart offers insights into appropriate wire speeds for various material thicknesses and types in MIG welding. It aids in the optimal setting of your MIG welder for effective, high-quality welds.

Table of Contents

Table of Wire Speed for MIG Welding

This table is a general guide; actual settings can vary based on specific conditions, welding machine, and type of wire used.

What Impacts MIG Welding Wire Speed?

Several factors influence the speed of the MIG welding wire. Material thickness is a primary factor – the thicker the material, the higher the wire speed and amperage setting required. The type of metal (e.g., stainless steel, mild steel) and wire (e.g., solid wire, flux cored wire) also affects the wire speed. Lastly, the welding position and your own welding technique can alter optimal settings.

From my years of experience, these variables make every welding job unique. A slight change in any of them can significantly affect the quality of your weld, so always keep them in mind when adjusting your wire speed.

This is the most commonly welded metal and often used as a benchmark for setting the wire speed in MIG welding. Mild steel has a relatively lower melting point than other metals, which usually requires a moderate wire speed.

Stainless Steel

Stainless steel has a higher melting point than mild steel. Consequently, it generally requires a lower wire speed to maintain a steady, controlled weld pool and prevent burn-through.

Aluminum conducts heat very effectively and has a lower melting point, leading to its base metal heating up quickly during welding. This requires a higher wire speed to compensate for the quick heating and melting, often making aluminum more challenging to weld than steel.

How to Set the Wire Speed for MIG Welding?

Setting the wire speed for MIG welding involves understanding the correlation between wire speed, voltage, and amperage. A higher wire speed requires a higher voltage to maintain a stable arc.

Consult your MIG welder’s chart for a rough guide on wire feed speed and voltage settings according to material thickness. From there, it’s fine-tuning based on your specific scenario and welder’s feel. A too slow wire speed might result in a weak weld, while a too fast speed may cause the wire to burn back towards the contact tip.

Wire Speeds for Common Welding Scenarios

• Welding Thin Material: You’ll need lower wire speeds when welding thin materials like sheet metal . It prevents the risk of burn-through.
• Welding Thick Material: A higher wire speed is required to achieve good penetration for welding thicker materials.
• Vertical Welding: A slower wire speed helps prevent the weld pool from sagging when welding vertically.

In my own experience, welding stainless steel requires a particularly fine balance. It’s less forgiving than mild steel and needs careful wire speed adjustment to get just the right penetration without burning through.

How to Control the Wire Speed on a MIG Welding Machine

Most MIG welders come with a wire feed speed dial. This knob or button allows you to increase or decrease the speed at which the wire is fed into the weld joint .

If you’re new to welding, start with your machine’s suggested settings and make incremental adjustments. Be sure to practice on some scrap metal first. Over time, you’ll understand how adjustments affect your weld quality.

Tips for Selecting the Correct MIG Welding Wire Speed

• Use a Welding Calculator: A welding calculator is a valuable tool for beginners. It calculates appropriate settings based on the type of metal, thickness, and wire type.
• Practice on Scrap Material: Before starting your project, practice on a scrap piece of the same material. This way, you can fine-tune your settings without affecting your project.
• Listen to Your Weld: A good weld sounds like sizzling bacon. If it pops and spatters, your wire speed might be too high.

Some welding machines give you a wire speed in terms of 1,2,3 out of 10. This will relate to a specific inches per minute speed. It is good to understand what your particular welding machine uses so when you move from machine t machine you can adjust more asily.

As an experienced welder, I’ve learned that there’s a certain art to selecting the correct wire speed. It takes practice, patience, and willingness to make and learn from mistakes.

Understanding your MIG welding wire speed chart and how to manipulate the wire speed according to your welding scenario is key to achieving high-quality welds. Whether you’re a novice or a seasoned welder, the chart, combined with your experience and judgment, is an indispensable tool.

Remember, practice makes perfect, and every piece of metal has a story to tell.

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The Ultimate Guide to MIG Welding

March 2, 2021

There are a few factors that will influence the type of welding that will work best for you. How big is the job? Are you welding indoors or outdoors? How thick is the metal you want to weld? What’s your budget? These are all things to consider when deciding which type of welder you’ll need.

Quick Navigation

Machine setup.

• Torch Setup
• Weld Preparation

Making the Weld

What is mig welding.

Metal Inert Gas (MIG) welding is an arc welding process in which a solid wire (the filler metal) is continuously fed through the welding machine and into the weld pool that’s created by the arc to form a weld.

The process of MIG welding is semi-automatic, as the machine does all the wire feeding for you. This is why MIG welding is considered one of the easiest types of welding to learn and a great place to start for beginners.

• Gas vs gasless
• Voltage/wire speed setup

1. Gas vs Gasless

There are two ways to MIG weld. The first (and most common) is with gas. The gas is used to shield the weld metal from any outside contaminants when welding. The second is gasless, and the filler metal used has a flux core, which protects the weld instead of gas.

If you’re using a shielding gas for your weld, there are a few to choose from, as different metals require different shields. The best gas to use for mild steel and stainless steel is a mixture of argon and carbon dioxide (75% Ar/25% CO2); however, straight carbon dioxide works as well. You can also add a small amount of oxygen to the ArCO2 mix. If you’re welding with aluminium, then you’ll need pure argon for your shielding gas.

When you’re using gas, all you need to do is attach the regulator to the tank, attach the gas hose from the welding machine to the regulator and set your gas flow. Every UNIMIG machine (except the VIPER 135) comes with a gas regulator, so don’t worry about having to buy your own.

The regulator comes with two dials. One shows how much gas is still in the tank, and the second shows your gas flow rate. Twist the regulator valve to set how much gas flow you want for the weld. UNIMIG recommends an 8-12L per minute gas flow rate for all MIG welding, and these recommended settings can be found on the guide table inside each machine.

If you’re welding outdoors with gas, you’ll find you may need to turn up the gas flow or set up a cover, as the breeze can affect how much gas is reaching the weld pool. If you’re shielding gas is being blown away, then the weld will be prone to defects like porosity (the Swiss cheese look).

The polarities will also require different setups depending on whether you have chosen gas or gasless welding. Gas welding with aluminium, stainless steel, and mild steel all require an electrode positive polarity. This means that you need to insert the polarity cable into the Positive (+) panel mount and the earth clamp (which comes provided) into the Negative (–) panel mount.

If you are using gasless wire, then the polarity is switched; the polarity cable would go into the Negative (–) and the earth clamp into the Positive (+) . While some machines are limited to gas or gasless only, at UNIMIG, all of our MIG welders are capable of both processes . A good example is the VIPER 185 MIG/TIG/Stick Welder , a multi-process machine made specifically for home welders, which will let you trial every type of welding you can think of (except AC TIG).

Regardless of whether you are using gas or gasless wire, your earth clamp will need to be attached to your workpiece (the metal you’re welding) or something metal that will conduct to your workpiece nearby; otherwise, the machine won’t weld.

Each roller comes with two grooves; these are the wire sizes (e.g. 0.6mm & 0.8mm). You’ll need to make sure the roller groove size is the same as the wire you are using. To replace a roller, unscrew the retaining cap and take the old roller off. Place the new roller on (lining up the keyway on the roller with the key on the machine) and re-screw the retaining nut.

MIG welding torches come with a Euro connection that plugs directly into the front of the machine.

3 types of MIG torches

• Binzel style
• Tweco style
• Bernard style

The main difference between these three torch types is that they were initially made by different manufacturers. Though the consumables for each look the same, you have to match your consumable type to the torch type; otherwise, they won’t fit.

Every UNIMIG MIG machine comes with a Binzel style torch, but all three are available for purchase.

A liner guides your wire inside the torch lead, and this liner ensures the wire makes it out of the torch tip. You may need to change your liner before you feed your wire through, as these liners – much like the rollers – will only fit specific sizes.

Let’s use an example. The RAZOR MULTI 220 has a wire size range of 0.6mm-1.2mm. If you started with a weld that only needed 0.6mm wire and then changed to a weld that needed 1mm wire, you’d need to change liners.

To change a liner:

• Remove MIG torch front end parts.
• Remove the liner retaining nut.
• Carefully pull out and completely remove the existing liner. Ensure MIG torch is completely unravelled until setup is complete.
• Carefully feed in the new liner down the torch lead all the way to exit the torch neck.
• Fit the liner retaining nut and screw only 1/2 way down.
• Snip the excess liner off, about the length of the where tip holder sits past the end of the torch neck.
• Replace the front end parts.
• Fully screw down the liner retaining nut and nip it up tight. This compresses the liner inside the torch cable assembly preventing it from moving during use and ensures good wire feed.

When you’re changing your liner, it’s best to keep the torch entirely straight and go slowly, as you don’t want to kink the liner itself.

There are separate liners for steel wires and aluminium wires. If you’re going to use a standard MIG torch for an aluminium wire, you’ll need an aluminium specific liner (in the correct size).

This liner goes in and out the same way as steel liners, but you have to attach a neck spring on the top of the liner before inserting it. The neck spring keeps the liner ridged so it can be fed into the torch with no issues and keeps the wire from kinking.

When you’re welding, try to keep the torch hose as loosely looped (or straight) as possible because it will minimise the chance of kinking the wire inside.

As well as your standard MIG torches, you can also get an aluminium specific torch, called a ‘spool gun’. Spool guns are set up slightly differently than the MIG torches, as the wire spool is not connected in the machine but in the gun itself.

The spool holder can only hold 1kg rolls, so if you’re doing a lot of aluminium welding , it’ll run out faster than in a machine, and the gun is going to fatigue your hands faster.

The benefits of a spool gun for aluminium are worth it, though. Aluminium is a softer metal than steel, so it has its own roller grooves and specific torch liners. The softness of aluminium means that it’ll kink way easier than steel will in a 4m torch despite all that. There’s no stopping it; it’s just a more difficult metal.

This is where your spool gun comes in. Because the wire is loaded into the gun (and then fed through the engine on the gun the same way the wire is fed through a machine’s roller mechanism), it has less distance to travel and less chance to kink.

Aluminium and soft wires are best for spool guns, though you can still run steel through them, as there are rollers available for both.

Most machines will include a switch inside them that is labelled ‘standard/spool gun’. Make sure this is flipped to the type of torch you have connected; the torch won’t run if the switch is on the wrong setting.

Note : If you have a water-cooling torch, you will also need to attach the blue and red water cables to the welding machine and the water cooler so that the water can flow through the torch.

4. Wire Spool

Before you begin, it’s essential that the filler metal you purchase matches the metal you plan to weld (your parent metal). Thanks to chemical compounds, mismatched metals won’t weld together properly unless you are using a filler metal capable of doing this, and the weld will be terrible quality.

The wire spool is like a loaded spring, so when you first undo the wire, don’t place it straight down onto a table or other surface as it will unravel, and you’ll have to clip off everything that has unwound.

Unfortunately, you won’t be able to rewind it because it’ll no longer be precision wound, and there’ll be a much higher chance that the wire will birdnest inside the wire feed mechanism, halting your weld.

The spool attaches inside the machine on the spool holder, which consists of a shaft and a nut. There is a locating lug on the back plastic plate of the spool holder that you need to line up with the locating hole on the wire spool. These look like a small round bump and dent, respectively. Once you’ve lined them up, slide your spool onto the shaft and screw your nut back in to lock the spool into place.

You’ll need to feed the first part of the wire into the inlet guide, over the roller and into the beginning of the guide tube before you let go of it to stop it from unravelling.

Now that the wire spool is attached inside the machine, feed it through the torch until it sticks out of the torch nozzle. You can feed the wire through in two ways; hold down the trigger on the torch or press the feed wire button inside the machine.

When feeding through a new spool of wire, it’s a good idea to remove the nozzle and contact tip from the end of the torch so that the wire doesn’t catch on them and birdnest inside the machine. Both parts screw on and off with ease, so there’s no hassle.

With a new spool, you’ll also need to adjust the tension on the wire. Feed your wire until about 50mm (5cm) hangs out of the torch tip.

Lock the tension lever and decrease the tension by rotating counter-clockwise so that the wire slips (the rollers are spinning, but the wire doesn’t move) when the trigger is pulled. Now turn your tension lever clockwise 180° to increase your tension and grip the exposed wire between your thumb and forefinger (in gloves, the wire gets hot) with light pressure.

Pull the trigger again while holding the wire. If the wire slips again, repeat the process, rotating the tension lever clockwise by 180° each time, until you can’t stop it with your fingers, and it feeds smoothly. Be careful though, too much tension can flatten your wire.

Once you’ve sorted your tension, trim any excess wire hanging out of the tip. You want your wire to stick out of the torch nozzle by roughly 1cm. If the wire sticks out too far, trim it back. If you start with too much wire, it will just burn off. Some machines have a burnback function that allows you to determine the wire’s burnback after your finish welding as well.

5. Voltage and Wire Speed

Every UNIMIG welding machine comes with a User Manual and Setup Guide, which provides a good starting point for your machine settings. It gives a detailed description of which wire speed and voltage you’ll need for a range of metal types, wire sizes and parent metal thicknesses. It also includes the gas flow rate that is recommended for each of these.

Metal Preparation

Unfortunately, MIG isn’t as forgiving as stick welding, so you’ll need to either wire brush or grind your workpiece so that it’s clean. Otherwise, you won’t get a quality weld.

Starting Your Weld

Now that your machine and workpiece are set up, you’re ready for the next step: starting the weld. With the voltage and wire speed set, the rest of the welding is up to you.

There are three main factors to consider when doing a weld:

• Travel angle & distance
• Travel speed

This is true regardless of whether you are TIG, MIG or stick welding.

1. Work Angle

Your work angle is your torch in relation to the angle of the joint. There are a few different joint types, and several positions these joints can be found.

(These angles do not include your travel angle, which we’ll talk about next.)

The main thing that your weld’s position will affect is whether or not you’ll be fighting against gravity as you go. You’ll usually need to increase your travel speed and lower your amps to keep the molten metal from dripping, so while you’re learning, flat positions are best.

2. Travel Angle & Distance

When MIG welding, you can travel at a pushing or a pulling angle, though it does depend on which wire is in the machine.

If you’re using mild steel, stainless steel or aluminium, you’ll want to travel at a pushing angle (torch over the weld pool pushing towards the metal).

If you’re using flux-cored wire (gasless), you’ll want to travel at a pulling angle (torch in front of the weld pool and dragging towards the metal).

Whether you’re pushing or pulling, you want to keep your torch at a 10° to 15° angle. If your angle becomes too deep or parallel with the metal you’re welding, you increase the spatter amount, decrease penetration, and create more mess that you’ll have to clean up later.

For example, say you’re welding in a fillet joint (a corner join) with a standard steel wire. Your torch will be angled into it at a 45° angle, and then you’ll angle slightly to the side (in a push direction) so that your gas can cover the weld pool and in front of the weld as you go.

The other important thing to watch is the distance of your wire ‘stickout’. You want to maintain the 1cm of stickout throughout the joint for the best weld. If your wire is sticking out too far as it’s feeding and your torch nozzle is getting further away from your workpiece, it will cause a few problems.

The first problem is that your feeding wire acts as a resistor, so the longer it is coming out of the torch and into the weld pool, the lower your machine will drop the amps, so it won’t run as well. The second problem is that your shielding gas will no longer be able to reach your weld pool, and you’ll increase the number of defects – like porosity – in your weld.

3. Travel Speed

Travel speed is how fast you are moving the torch along the weld. This is separate from the wire speed, but the two do impact each other.

If you’re moving too fast for your set wire speed, then there’ll be nothing being fed into the weld pool to create a proper weld.

On the other hand, if you’re moving too slowly or you have too much wire being fed through, you’re going to have a fat weld join that will need to be ground back, causing a lack of fusion on the toes (edges of the weld).

You want to move at a speed that corresponds with your settings. Keep your travel speed consistent across the entire weld for the best quality result.

Place your cleaned workpiece in front of you in a way that when you begin welding, your hands can move freely and steadily all the way along the joint. It’s a good idea to have something to steady your hands against as they go along the weld so that you can maintain your angle and distance.

Check that your earth clamp has been attached to a metal surface, such as a (clean) metal workbench or the workpiece, because if your earth clamp isn’t grounded, your machine won’t start.

If you’re making a fillet join, you can use a magnetic welding clamp to hold your two pieces of metal together. Aluminium isn’t magnetic, however, so a manual clamp will be needed.

The kind of wire you are using will determine the technique required when welding.

Push Technique (Gas-shielded Wires)

The wire is located at the leading edge of the weld pool and pushed towards the un-melted work surface. This technique offers a better view of the weld joint and direction of the wire into the weld joint.

The push technique directs the heat away from the weld puddle, allowing faster travel speeds and providing a flatter weld profile with light penetration – useful for welding thin materials. The welds are wider and flatter, allowing for minimal clean up/grinding time.

Pull Technique (Gasless Wires)

The gun and wire are pulled away from the weld bead. The arc and heat are concentrated on the weld pool. The base metal receives more heat, deeper melting, more penetration and the weld profile is higher with more build-up

Start with your tacks. Remember to flip your welding helmet down before you ignite your arc. Tacks are used to fuse the metals together at the edges, so you don’t have to hold them together while you’re trying to weld.

Line your torch tip and wire up with where you want to make your tacks (usually on the edges of the piece) and press the trigger of your torch. You’ll need to hold it continuously to maintain the arc. Hold it for a second or two until a small weld has formed, and then let go.

These won’t take more than a few seconds each to make; they only need to hold your joint together so you can make the proper weld without needing a clamp.

MIG welding itself is relatively easy once you’ve got the hang of your angles and speed; all you need to do is press the trigger and start pushing or pulling your weld along the joint.

A good way to tell if it’s going well is by how it sounds and how it looks while you’re doing it. A proper weld should sound like crackling bacon. Being able to identify this is something that takes a bit of experience, but if something is really wrong, you’ll notice pretty fast.

If you’re trying to weld thicker pieces of metal together, adjust your volts and wire speed accordingly.

Once you’ve run your weld along the joint, you’re done. You’ve made your first weld!

Because MIG welds do make spatter, and if you use a gasless wire with a flux core, some post weld work needs to be done. If you’ve used a flux wire, you’ll need to use a chipping hammer to take off the slag that formed its protective layer over the top of the weld.

If there is spatter everywhere, you can grind this off for a cleaner looking weld or, alternatively, you can use an anti-spatter spray before welding. If the weld is just for practice, it doesn’t matter how good it looks.

Just remember that dry runs and scrap metal are your friends. Practice running your welding torch across a piece of metal, maintaining your travel angle, distance and speed until you’re confident that you can keep all three of them consistent.

Once you’re happy with your performance on a dry run, try it again on some scrap metal before you move on to the piece you’re planning on welding. If you don’t get it the first attempt, that’s fine; no one’s expecting you to be a welding expert on your first go. Practice makes perfect.

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MIG Welding: Everything You Need to Know

February 3, 2024

MIG (Metal Inert Gas) welding, also known as GMAW (Gas Metal Arc Welding), is a popular welding process that uses a continuous solid wire electrode to join metals together.

An electric arc is created between the base metal and the wire, which heats up the metals to form a weld pool. Protective gas, usually argon or carbon dioxide, flows around the weld area to shield it from contamination.

Table of Contents

How does it work, mig vs stick welding, mig vs tig welding, mig vs flux-cored welding, welding machine, welding gun, welding wire, proper welding technique, voltage and wire speed settings, stainless steel, common weld defects, how to fix defective welds.

Here’s a quick rundown of how MIG welding works:

• An electric current runs through the MIG welding gun and wire electrode.
• When the wire touches the base metal, an electric arc is created that generates heat up to 6,000°F.
• The heat from the arc melts the base metal and the end of the wire, forming a molten weld pool.
• As the wire feed continuously moves forward, metal from the wire fills the weld joint.
• The protective gas shields the weld area from oxygen and other contaminants during welding.
• The molten metal then cools and solidifies to form a strong metallurgical bond.

The main advantage of MIG welding is that it’s faster and easier to learn than other welding methods like stick or TIG welding.

The wire feed system allows welders to join metals with minimal slag cleanup. Overall, MIG welding is a versatile, efficient, and high-quality welding process for projects and repairs.

MIG welding vs other welding processes

MIG welding has some key differences from other common welding processes like stick (SMAW), TIG (GTAW), and flux-cored welding:

• Heat Control: MIG welding offers more control over heat input compared to stick welding, allowing faster travel speeds.
• Slag Removal: MIG welding produces minimal slag that chips off easily. Stick welding leaves heavy slag that must be chipped/brushed off.
• Speed: The continuous wire feed of MIG welding allows faster welding than manually “dipping” the electrode rod like stick welding.
• Skill Level: MIG welding is easier to learn than TIG which requires greater manual dexterity.
• Speed: MIG welding allows higher deposition rates than TIG which tends to be slower.
• Automation: MIG welding can be automated more easily compared to manual TIG welding.
• Shielding Gas: MIG uses an external shielding gas, while flux-cored uses gas generated from the wire itself.
• Metal Transfer: MIG offers a more controlled, spray-like metal transfer vs more globular transfer of flux-cored.
• Weld Quality: MIG typically can produce higher quality and aesthetic welds than flux-cored welding.

So in summary, MIG welding strikes a good balance of being easy to learn while also offering great weld appearance and quality at reasonably fast speeds.

MIG Welding Equipment

The welding machine , also called a welding power source, provides power for MIG welding. Key components include:

• Power transformer – Steps down high incoming voltage to lower “welding” voltage.
• Rectifier – Converts AC to DC current for welding. May be built-in or separate unit.
• Wire feed motor – Drives the wire electrode through the welding gun.
• Contactor – Turns welding power on/off.
• Control circuit – Adjusts current and voltage for different wires/applications.

Also read: Best Mig Welder for Beginners

There are several types of MIG welders to choose from:

• Transformer MIG – More basic units best for home/hobby use. Limited output settings.
• Inverter MIG – More advanced design with improved performance. Ideal for precision welding.
• Multi-process – Combines MIG welding plus other processes like stick and TIG in one unit.
• Spool gun MIG – Special gun for easier welding of aluminum. Attaches to standard MIG machine.

When selecting a MIG welder, key factors to consider are: welding amperage, duty cycle rating, number of voltage settings, wire feed speed control, and spool gun capabilities if welding aluminum.

The MIG welding gun, sometimes called a “torch”, directs current and shielding gas to facilitate welding.

Standard MIG guns have a handle, trigger switch, contact tip, nozzle, gas diffuser, liner, and wire feed rollers inside. Key functions include:

• Trigger – Activates welding power when pulled.
• Contact tip – Transfers current to the welding wire. Made of durable copper.
• Nozzle – Focuses shielding gas coverage around the weld.

MIG guns are air or water-cooled. Air guns are cheaper but may overheat on long welds. Water-cooled MIG guns cost more but resist overheating.

Guns come in different lengths up to 25+ ft. Longer guns allow easier access to tight welds. Guns wear from wire friction and must be replaced over time.

Optional spool gun attachments allow easier welding of aluminum. The lighter, softer aluminum wire feeds better through shorter distances.

MIG welding uses a thin wire electrode fed continuously through the welding gun. Common wire sizes are: 0.023”, 0.030”, 0.035” and 0.045” diameter. Thicker wires allow faster deposition but less precision.

Wire is packaged on 10-60 lb spools and fed by the wire feed system. Flux-cored wires contain flux materials and shielding compounds inside an outer sheath. Common wire types include:

• Mild steel – Low carbon steel wire for welding plain carbon steels.
• Stainless steel – Special wires for stainless steels to match composition.
• Alumin Aluminum – Softer wires specifically for welding aluminum alloys.
• Flux-cored – No need for external shielding gas. More spatter.

Choosing the correct wire type/size for your base metal is important for proper weld quality and appearance.

MIG Welding Technique and Settings

Good welding technique is crucial for quality MIG welds. Key points include:

• Steady hand – Hold the gun steady as you move to make a uniform weld.
• Constant distance – Maintain about 3/4 inch stickout and contact tip to work distance.
• Consistent travel angle – Keep a 5-15 degree push angle along the joint.
• Proper speed – Move the gun at a steady rate to prevent cold laps or burn through.
• Full coverage – Overlap each weld pass slightly to fill the joint completely.

It takes practice to coordinate the gun angle, travel speed, and arc length while aiming the weld puddle precisely where you want it. Developing good muscle memory and “puddle control” separates welding novices from skilled welders.

Choosing the right voltage and wire speed settings is vital for proper weld penetration and bead shape.

• Voltage – Increasing voltage gives a “hotter” arc that penetrates deeper into the base metal.
• Wire Speed – Faster wire speed provides more filler metal deposition into the joint.

For a given wire size, the manufacturer provides voltage and wire speed ranges to follow. Choosing settings in the middle is a good starting point. Specific adjustments from there depend on factors like joint type/thickness, torch angle, travel speed, and operator technique.

As a rule, set the voltage based on penetration needs, then increase wire speed to get the desired weld size. The goal is a steady “hissing” arc sound, smooth metal deposition, and good tie-in at the weld toes.

MIG Welding Different Metals

Low carbon steel is the most common metal welded with the MIG process. Key tips include:

• Use ER70S-6 wire for all-position welds
• Select 75/25 shielding gas (75% argon/25% CO2) for short circuit transfer
• Use higher voltage settings for thicker plates
• Lap each weld pass 30-50% over previous pass

MIG creates strong uniform welds on thin gauge steels like sheet metal up to 1/2 inch thick structural steel plates. It allows fast welding speed compared to stick or TIG on plain carbon steel applications.

MIG welding different stainless steel alloys requires matching the wire composition and using pure argon shielding gas to prevent oxidation.

• Use ER308L or ER316L wire for common austenitic stainless
• Select 100% argon shielding gas
• Clean surfaces well and use stainless brush to remove slag
• Use lower heat and travel speed to prevent distortion

The MIG process allows stainless steel welding with relatively easy technique. Pay special attention to post-weld cleanup to restore the corrosion resistant surface.

MIG welding aluminum requires some special considerations:

• Use 4043 aluminum wire to match base material
• Argon shielding gas prevents oxidation of soft aluminum
• Slow wire speed required for good metal transfer
• Use lower heat input to minimize burn through
• Spool gun MIG torch improves wire feedability

The trickiest part of aluminum MIG welding is getting the wire to properly short circuit and transfer across the arc gap. This requires very precise voltage control.

Overall it’s more difficult than steel MIG welding. But with attention to gun angle and technique, quality aluminum welds can be made.

Troubleshooting MIG Welds

Some common MIG weld defects and how to avoid them include:

• Porosity – Gas bubbles trapped in weld. Check gas flow, clean material, dry welding wire.
• Spatter – Scattered bits of metal. Adjust voltage or wire speed.
• Undercut – Groove melted at weld toe. Decrease travel speed.
• Burn-through – Hole in base metal. Reduce voltage or increase travel speed.

Paying attention to proper machine settings, welding technique, joint fit-up, and base material condition can help avoid flaws in MIG welding.

Repairing a defective MIG weld correctly is important for strength and appearance. Steps include:

• Clean weld by chipping flux or brushing slag
• Grind defect down to sound metal with angle grinder
• Set up welding machine for thinner material
• Use stringer beads and/or wider weave technique
• Fully fuse repair weld into sides of groove
• Blend repair for minimized distortion

It takes some welding skill to tie-in repair welds properly. But with care and the right technique, defective MIG welds can get fixed to restore a quality joint.

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How to Master 2FG Position Welding: A Comprehensive Guide

Welding is an essential skill in various industries, from construction to manufacturing. Mastering different welding positions  can significantly enhance your capabilities and versatility as a welder. The 2FG position, which stands for 2 Flat Groove, is one of the fundamental welding positions used in many applications. At Megmeet Welding Technology , we provide the tools and knowledge to help you become proficient in 2FG position welding. This blog will guide you through the steps to quickly master this critical welding position.

I. Introduction to 2FG Position Welding

1) what is 2fg position welding.

The 2FG welding position refers to a horizontal fillet weld. In this position, the welder works on a joint where one piece of metal is placed horizontally, and the other piece is placed vertically, forming a right angle. The "2" indicates the horizontal position, and "F" stands for fillet weld, while "G" is an abbreviation of groove weld. The 2FG position is common in various applications, including structural welding, pipe welding, and fabrication.

2) Why Master 2FG Position Welding?

Mastering the 2FG position is crucial for several reasons:

Versatility: It's a common position in many welding applications.

Skill Development: Enhances your overall welding skills and prepares you for more complex positions.

Career Advancement: Proficiency in multiple welding positions increases job opportunities and earning potential.

II. Steps to Quickly Master 2FG Position Welding

1) grasp the basics of welding.

Before diving into practical welding, it's essential to understand the theoretical aspects of 2FG welding. Study the following:

Joint Preparation: Ensure the workpieces are properly aligned and clean.

Welding Parameters: Familiarize yourself with the appropriate settings for your welding machine, including voltage, amperage, and travel speed.

Safety Precautions: Always wear appropriate personal protective equipment (PPE) and follow safety guidelines.

2) Gather the Right Equipment

Using the right equipment is crucial for achieving high-quality welds in the 2FG position. Ensure you have the following:

Welding Machine: A reliable machine with precise control over welding parameters.

Electrodes: Suitable electrodes for the material you're welding.

Clamps and Fixtures: To secure the workpieces in place.

PPE: Including welding helmet, gloves, and protective clothing.

3) Practice Proper Technique

The technique is key to mastering 2FG position welding. Follow these tips for optimal results:

Maintain a Consistent Angle: Keep the electrode at a consistent angle (usually around 15 degrees) relative to the workpiece.

Steady Travel Speed: Move the electrode at a steady speed to ensure even weld beads and proper penetration.

Control Heat Input: Adjust the welding parameters to avoid overheating and distortion of the workpiece.

Use Tack Welds: Secure the workpieces with tack welds before starting the main weld to maintain alignment.

4) Focus on Bead Placement

Proper bead placement is crucial for a strong and visually appealing weld. Practice the following:

Stringer Beads: Use stringer beads for better control and penetration.

Weave Beads: If needed, use a slight weaving motion to cover wider joints.

Overlap: Ensure each pass slightly overlaps the previous one for a seamless finish.

5) Inspect and Correct

Regular inspection of your welds helps identify areas for improvement. Look for the following:

Consistency: Check for consistent bead size and spacing.

Penetration: Ensure the weld has adequate penetration without burn-through.

Appearance: Aim for smooth, clean welds with minimal spatter and slag.

6) Seek Feedback and Mentorship

Learning from experienced welders can significantly accelerate your progress. Seek feedback and mentorship from skilled professionals. They can provide valuable insights and tips to refine your technique.

7) Continuous Practice

Mastery comes with practice. Set up a regular practice schedule to hone your skills. Challenge yourself with different materials and joint configurations to build confidence and versatility.

II. Common 2FG Position Welding Mistakes and How to Avoid Them

Welding in the 2FG position (2 Flat Groove) presents its own set of challenges, even for experienced welders. The following is some common 2FG position welding mistakes and their solutions to avoid them.

1. Inconsistent Travel Speed

Mistake: Welding at inconsistent speeds can result in uneven bead appearance, insufficient penetration, or excessive heat input.

Solution: Maintain a steady travel speed throughout the weld. Practice controlling the speed of your hand movement to ensure uniformity. Using a travel speed gauge or counting method can help maintain consistency.

2. Incorrect Electrode Angle

Mistake: Varying the electrode angle during welding can lead to inconsistent penetration and bead shape.

Solution: Keep the electrode at a consistent angle relative to the workpiece. For most applications, a slight forward angle of 5-15 degrees is recommended. Practice maintaining this angle throughout the weld to achieve consistent results.

3. Poor Joint Preparation

Mistake: Neglecting proper joint preparation can result in inadequate fusion, lack of penetration, or weld defects.

Solution: Take the time to properly clean and prepare the joint before welding. Remove any contaminants, such as rust, paint, or oil, using a wire brush or grinder. Ensure proper fit-up and alignment of the workpieces to promote optimal weld quality.

4. Overheating the Workpiece

Mistake: Applying excessive heat to the workpiece can lead to distortion, warping, or burn-through, especially in thinner materials.

Solution: Control heat input by adjusting welding parameters such as amperage and travel speed. Avoid lingering in one area for too long, as this can cause localized overheating. Use intermittent welding techniques and allow the workpiece to cool between passes if necessary.

5. Poor Arc Control

Mistake: Inadequate arc control can result in spatter, erratic bead shape, or difficulty maintaining a stable arc.

Solution: Practice establishing and maintaining a stable arc throughout the weld. Maintain a consistent arc length, typically around 1/8 to 1/4 inch, for optimal control. Adjust the welding parameters to achieve the desired arc characteristics, such as arc length and arc force.

6. Insufficient Cleaning Between Passes

Mistake: Failing to clean between passes can result in contamination, lack of fusion, or inclusion of slag in the weld.

Solution: Clean the weld area between passes to remove any slag, spatter, or debris. Use a wire brush or compressed air to clean the weld surface thoroughly. Ensure the joint is clean and free of contaminants before starting each pass.

7. Neglecting to Back-Gouge

Mistake: Skipping back-gouging in groove welds can lead to incomplete fusion or lack of penetration, especially in thicker materials.

Solution: Back-gouge the root of the joint to remove any oxidation, scale, or impurities that may hinder weld quality. Use a grinder or gouging tool to create a clean, V-shaped groove for improved weld penetration and fusion.

8. Improper Shielding Gas Coverage

Mistake: Inadequate shielding gas coverage can result in oxidation, porosity, or contamination of the weld.

Solution: Ensure proper gas flow and distribution during welding to maintain adequate shielding gas coverage. Adjust the flow rate and nozzle position as needed to protect the weld from atmospheric contamination. Monitor gas flow and purity regularly to prevent issues.

9. Failure to Control Weld Pool Size

Mistake: Allowing the weld pool to become too large or too small can affect bead shape, penetration, and overall weld quality.

Solution: Control the size of the weld pool by adjusting welding parameters and technique. Use a slight weaving motion or oscillation to control bead width and ensure adequate sidewall fusion. Practice maintaining a consistent weld pool size for optimal results.

10. Lack of Practice and Experience

Mistake: Insufficient practice and experience can lead to inconsistent weld quality and difficulty troubleshooting welding issues.

Solution: Practice regularly in the 2FG position to develop your skills and familiarity with the process. Experiment with different techniques, materials, and welding parameters to broaden your experience and proficiency. Seek guidance from experienced welders and take advantage of training opportunities to enhance your skills.

IV. Conclusion

Mastering 2FG position welding is a valuable skill that can enhance your welding capabilities and career prospects. By understanding the basics, using the right equipment, practicing proper technique, and continuously improving through practice and feedback, you can quickly become proficient in this essential welding position. At Megmeet Welding Technology, we are dedicated to helping you achieve excellence in welding. Our advanced welding solutions and expert guidance are here to support your journey to mastery.

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3.  Welding Positions and Joint Types: 1G, 2G, 3G, 4G, 5G, and 6G

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Travel speed

• Thread starter Muhammad
• Start date Aug 18, 2020
• Aug 18, 2020

your using a lincoln machine ? it dosnt look right too bulbous if im honest here weld flow looks ok but its too high on the weld id expect more flow not too sure on your shielding gas flow though seems a bit high but could be wrong someone else might point you in the right direction soon though  

• Aug 19, 2020

Surely the only consequence of too much gas is wasted gas - at high amps anyway?  

minimutly said: Surely the only consequence of too much gas is wasted gas - at high amps anyway? Click to expand...

The weld speed is way too slow, far to much weld metal  

AdeptusMechanicus wanna be.

Looks either cold or slow, how's the uderside of the plate ?  

Jack of some trades, Master of none

you're going to need well over 400 IPM with that size of wire. Try around 420-450. Leave volts etc where they are.  

backpurge said: The weld speed is way too slow, far to much weld metal Click to expand...

Jay1st said: Looks either cold or slow, how's the uderside of the plate ? Click to expand...

they look much better than before  

can try lowering the speed  

• Aug 20, 2020

You need to run some joints before you really know what's right. MIG beads on a plate paint a false picture. Looks set about right, even if there isn't enough amps. Try a fillet weld. You'll need the wire speed up to over 400 IPM for penetration, like I said.  

Munkul said: You need to run some joints before you really know what's right. MIG beads on a plate paint a false picture. Looks set about right, even if there isn't enough amps. Try a fillet weld. You'll need the wire speed up to over 400 IPM for penetration, like I said. Click to expand...

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Cnc machining, finishing & assembly, knowledge base, about service, policies & terms, stainless steel welding – challenges, methods & best practices.

Stainless steel is a widely used metal used by most sectors due to its proven durability, corrosion resistance and aesthetic appeal. It shares similar properties to carbon steel but with at least 10.5% chromium content for added resistance to corrosion.

Let’s explore the unique characteristics of welding stainless steel to maximise its overall result.

The Challenges in Welding Stainless Steel

Stainless steel welding, in particular, presents a unique set of challenges in welding from its mechanical properties . Its various grades and types (such as austenitic, ferritic, martensitic, precipitation-hardened , Duplex, etc) add an extra layer of complexity to the subject.

Let’s explore a few of the challenges in welding stainless steel and learn how to overcome them.

Warping & Cracking

Stainless steel has low thermal conductivity and high thermal expansion, making it susceptible to warping and cracking . Excessive heat input during welding or a rapid change in the temperature puts the metal under stress, resulting in distortion as it cools down.

There are a few ways to prevent warping and cracking, one of which is through working with lower heat input. While it may seem logical, it also may result in poor weld quality due to incomplete fusion between the workpieces. So it is always important to strike a balance between the two extremes. Another solution is to create a heat sink by clamping copper or brass behind the seam, absorbing unnecessary heat into the copper alloys .

Stainless steel is known to have high corrosion resistance, yet excess heat may still generate rust in the weld. It may also form as the carbon from the filler material contaminates the heat-affected zone .

Choosing an optimal welding temperature and a stainless steel filler alloy depending on the job greatly reduces the risk of forming rust in the material.

Welding Dissimilar Steels

Welding dissimilar metals or various stainless steel grades together can be challenging, especially if their melting points would be far apart. It might cause great trouble in fusing the metals effectively.

Selecting the optimal filler rod is necessary when welding stainless steel and another alloy. Preheating the metals can also alleviate this problem.

Switching Between Jobs

The lower melting temperature of stainless steel (1375 – 1530°C) compared to mild steel (1425-1540°C) might become problematic when switching between the two.

Toxic Fumes

Stainless steel welds produce toxic fumes in the form of hexavalent chromium gas . It develops as the chromium oxide layer is destroyed and may occur either during the heating or cooling process.

An effective breathing mask combined with proper ventilation in the area is key to ensuring the welder’s safety.

Stainless Steel Welding Methods

Depending on the project’s requirements, several welding processes can be performed to join stainless steel parts. We’ll highlight a few of those processes but this is not an exhaustive list, processes such as plasma welding , electron beam welding, submerged arc welding , etc are all perfectly capable of welding stainless steels as well.

TIG Welding (GTAW)

TIG welding is widely used in the fabrication sector for stainless steel since it has a stable arc and the process is automated. In the TIG process, the heat applied to the weld can precisely be controlled through a foot pedal or finger control, minimising the possibility of warping. TIG welding machines can also switch between AC and DC polarities, offering flexibility and convenience simultaneously.

Gas tungsten arc welding stainless steel is rather costly since the process needs consumables such as shielding gas (usually pure argon) and optional filler rods. Selecting the right geometry and size of the electrode depending on the welding variables should definitely be considered beforehand.

MIG Welding (GMAW)

MIG welding is another popular choice for welding stainless steel. It offers faster speeds than TIG welding mainly thanks to its continuously fed electrode. One downside of this technique is that it doesn’t look as pleasing to the eye as properly executed TIG welds.

A Teflon wire liner in the MIG gun allows for a consistent wire feed to the weld pool and added protection from contamination. Backstepping, staggering or allowing the joint to undergo a bit of the cooling process helps avoid warpage since stainless steel retains heat well.

Shielded Metal Arc Welding (SMAW)

Stick-welding stainless steel is often the practical choice regarding cost, portability and simplicity. SMAW can be performed in almost any environment and thus is great for various repair jobs and welding stainless steel outdoors.

Thicker pieces of stainless steel (above 2mm) are most suitable for SMAW since it is harder to control the heat input than with other methods. Selecting the electrode (typical grades: 316, 308, or 312) is an important part of the project. Beware of slag removal after the welding as it might be a bit of a struggle.

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Flux Cored Arc Welding (FCAW)

Flux-cored arc welding stainless steel is sometimes preferred over SMAW since it generally creates a more uniform weld bead. FCAW can be performed with a shielding gas when working with varying material thicknesses or in demanding welding conditions.

A 10° drag angle allows the flux to rise at the weld pool and gives enough bead coverage.

Resistance Welding

Resistance welding ( spot welding , seam welding) stainless steel creates clean welds compared to arc welding processes since it doesn’t use filler material and has no risk of weld spatter. The high electrical resistance of stainless steel is also favorable since it can complete a weld in a short amount of time.

A good quality welder with sufficient power output is necessary for resistance welding stainless steel to prevent the areas close to the HAZ from deformities. It is recommended to have higher current and voltage values when welding stainless steels compared to, for example, copper and aluminium alloys due to the difference in electrical conductivity.

Friction Welding

Friction Welding Stainless Steel to Carbon Steel

Friction welding stainless steel, similar to resistance welding, doesn’t use consumables, making it an economical choice when the part geometries allow for it. It is most suitable for welding austenitic stainless steel due to its composition of chromium (16-26%) and nickel (8-22%).

Some factors that need to be considered are friction pressure, burn-off length and rotational speed. Some sub-types of friction welding may be suitable for specific applications: friction hydro pillar processing (FHPP), friction stir welding (FSW) and friction plunge welding.

Stainless Steel Welding Best Practices

Safety and preparation.

Preparation of equipment, materials and the work area is essential before engaging in any kind of welding process suitable for stainless steels. A dedicated stainless steel wire brush to prepare the metals will decrease the chances of contamination. Gloves, goggles and other protective gear will minimise the risk of accidents such as exposure to fumes and injury due to spatter.

Filler Metal Selection

Choosing the appropriate filler material depending on the scope of work is really important. Most of the time it should match the grade of the stainless steel, achieving almost the same properties. Other considerations in choosing filler material include weld joint design , aesthetics and overall weld performance.

An experienced welding provider understands the finer details of each stainless steel grade, weldable metals and welding method. It leads to a better choice when fine-tuning the parameters such as the power supply, torch angle, travel speed and deposition rate. Effective use of these welding parameters will help to achieve the highest quality welds.

Shielding Gas

The choice of shielding gas in processes such as MIG and TIG welding is crucial in protecting the weld pool from contamination. The correct shielding gas composition will reduce the risk of weld defects and improve the weld’s overall outcome.

Consider the variables of the welding project in determining the ideal heat input to weld stainless steel. Generally, the welding current should be about 20% less than for carbon steel to prevent corrosion .

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MIG welding wire speed and voltage chart

Check Flux Core Wire Speed And Voltage Chart

MIG wire speed chart metric

Read More- Difference between NR-211-mp & E71T-11? Difference between e71t-gs & e71t-11 .030 vs .035 flux Core Wire for welding

Table of Contents

How to calculate wire feed speed in MIG welding?

To calculate MIG welding wire feed speed, you need to multiply the necessary current of your welding by the flame rate connected to the wire’s diameter so that you can calculate the speed of the feed. Using this method, you can simply multiply the current of 100 amps by the 3-inch flame rate to determine a wire feed speed of 300 in. per min.

Welding inches per minute formula

This is a formula to count the welding and this formula is used for determining how long it will take to finish a certain welding project. This is a simple formula where you have to measure the length of welding in inches and later divide it by the elapsed time required to finish the weld in minutes. The outcome will be your desired welding inches per minute data.

How do you set wire speed and voltage?

There are several ways to set the voltage and wire speed of your welder. But here we will provide the easiest and effective way to set it. Please follow our step-by-step guide to set the voltage and wire speed of your welder as follows: 

• You need to use a single amp for every wire
• You should not try to weld through more than eight-inch material 
• As you know how to calculate welding inches per minute, so use that formula to find and set it at 250 inches per minute
• Now, start welding through your desired material
• Set voltage on your welding according to your requirement 
• Regulate the tension nuts properly
• Start welding once again with this right setting
• Finally, set the speed of the wire and the setting of voltage and wire speed will be visible.

You can watch this video to get a better understanding of the process:

What voltage is needed for MIG welding?

Though there are differences of opinion on this particular question as you will listen to people saying 220/230 volt required for MIG welding. But the popular theory is to use 240 volts for MIG welding on a single phase. But you should keep in mind while buying a MIG welder that 220/230/240 volts are almost the same thing so you should not be looking for a particular 240 volts MIG welder rather you can buy and later change it into a 240 volts welder. 

How do I set my MIG wire feed speed?

You can only get neat weld even with the wrong set of power on your MIG welder. Penetration can be too much or too little, but at least your welds will be clean. But with the right set of MIG wire feed speeds, you can have precise welding and penetration. This is what we desire and to get that there is no alternative to an experiment. Yes, you heard it right. You need to try experimenting on different speeds so that you can guess the right speed to weld and set it on your MIG wire feed. 

How thick can a 180 Amp MIG weld?

When you will buy a 180 amp MIG weld, the seller will notify you about that or you can check on the package of the product by yourself. A 180 amp MIG welder is capable of fusing up to an amount of 0.035 inches.

How does voltage affect MIG welding?

The voltage of MIG welding essentially supervises the length of the arc that is the gap between the wire filler alloy and the melted weld pool on the verge of defrosting within the arc. When the voltage will increase, the MIG weld ball will straighten out more as well as have an uprising ratio of width to depth. 

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I finally fired up my Millermatic 180 this weekend, using the supplied .030 and straight co2, local company only deals in 220cft tanks so I have plenty gas I only had some 1/8" thick angle and 1.2mm rhs section to experiment with. It appears that either the chart settings are way to high or I am doing something wrong as with the recommended settings for 1/8 I was getting holes very easily. I was only able to manage better when I turned down the voltage setting to 18ga and then play with the wire speed from there. Did both push and pull, I found it was safer with pull as push tended to get holes easier. I suspect my travel speed is too slow, however I am unsure of the relationship between the three(voltage, wire speed, travel) or at least what speed I should aim for, or should the puddle size be used as the primary guide and move before it gets too big and drops out.

Re: Newbie mig travel speed question

Porosity is usually caused by dirty metal or lack of sheilding gas when using solid wire and gas. Was your metal clean? It is best with solid wire and gas to grind off all the mill scale and clean off any paint, grease, rust, etc. in the weld area. What is your gas flow set to? 20 cfh works fine for most circumstances. Was there a breeze blowing? A breeze will blow away the gas. Put up a wind break, take the work inside, shield the weld with you body and free hand, or switch to self shielding fluxcore wire. What stickout length were you holding. Keep the tip to work distance no more than 1/2". Is your gas nozzle clean? Spatter deposits inside the nozzle and on the diffuser can mess up the gas flow/coverage. Is your nozzle all the way inserted on the torch? What angle are you holding the torch to the work? Laying the torch back too much can cause poor gas coverage. The nozzle should be close to vertical, about 10 to 20 degrees back. Finally, travelling too fast causes poor fusion, poor penetration, cold toes, or undercut if the heat is high enough, and uneven ropey looking humped up weld bead. Watch the puddle. Keep the wire on the leading edge of the puddle, but don't overrun the puddle and get out ahead of it. Keeping the wire too far back in the puddle is travelling too slow and cause the weld to be overfilled and toes to roll out and lap over. Move the torch at a consistent speed and watch the toes for even bead width as you go along.

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The figure that miller give for heat and wire speed should be really close if not right on. Keep in mind that MIG is a high speed process when you get it right. Once you have a puddle get moving but as said earlier don't out run the puddle. Having said that now set your machine as miller states and try to out run the puddle. Keep increasing travel speed slowly and when you do out run the puddle slow down a bit and you'll have it. Once you have it you'll hear that very distinct sound of a MIG running right and you'll be able to weld by ear when you have to.

Tough as nails and damn near as smart

yes, everything was more or less clean, gas was set betweel 20-30. I had the tip pretty close, maybe my angle was a little too much but not by much. I think my travel speed was the main issue. Definitely didn't have cold issues. Will go again later this week and post some pics.

I did some more tests last night trying to get a faster travel. I realize my main problem right now is I am using an old aquarium table frame as my welding table and it's only 32" tall whilst I am almost 6', so I am hunched over and cant move my arms easily to experiment with control. First project this weekend will be to try extending the legs. Was able to run some beads close to the factory charts on 16ga rhs. Push was safer, I find that when pulling it is easy to have wire stray in the trailing edge of the puddle and burn thru. There is a cold bump at the start though.

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