Updated 05.05.2021
WELDING
SEMI-AUTOMATIC M.i.G
(GMAW)
Metal Inert Gas
M.A.G
(GMAW)
MIG/MAG is a semi-automatic welding process that uses the heat of an electric arc to heat the filler metal (cored wire or solid wire) to its melting point. The wire coming directly from the torch is melted and left on the workpiece in the shape of drops. MIG/MAG can be automated and is effective for intensive use, especially in industry.
Metal Active Gas
Process principle The electric arc is formed under gas protection between the wire and the part to be welded, resulting in their fusion. The wire is continuously fed to the arc through the reel mechanism and the torch The weld pool is protected from the outside air by the protective gas.
Nozzle Contact tube Wire Protection gas Arc Weld pool Welding parts
Applications
Boiler making
Structural steelwork
Automobile
ADVANTAGE S • Higher productivity than other processes (continuous wire feed)
• Welding standard materials • High deposition rate at high intensity and good penetration • Simple weld cleaning (no slag, except on some cored wires)
• Welding in all positions. • Automatable
Shipbuilding
General Industry
Nuclear
DISADVANTAGE S • Outdoor welding is difficult due to draughts • Requires gas protection (in most cases) • More expensive than the coated electrode process (MMA) • Less quality than the TIG process
WELDING
SEMI-AUTOMATIC Materials and preparation steps Equipment required for MIG/MAG welding: Regulator
Wire reels
If welding with gas : Equip the welding machine with a gas cylinder and pressure regulator. The gas to be used depends on the weld :
Wire feeder integrated or separated
Steel (MAG): argon + CO2 (8 to 25% CO2 or 100% CO2 ) Inox (MAG): argon + CO2 (2,5% CO2 max) Aluminium (MIG) : Pure argon Earth clamp
Torch
If welding without gas : Equip the welding machine with a reel of "no gas" wire (cored wire). Change the roller, contact tube and torch nozzle for gasless welding.
Set up 1. Connect the MIG/MAG torch. Protect the contact tube and the nozzle by applying a release agent (optional).
2. Attach the earth clamp to the workpiece. 3. Adjust the wire tension and speed. Protection gas
Cooling system (if water-cooled torch)
Inverter or traditional commutator power source
4. Before welding, extend the wire 8 to 15 mm beyond the nozzle by pulling the trigger.
Protective equipment & consumables Before any welding activity, be sure to wear protective equipment:
Torch consumables
Nozzle
Welding helmet
Protective gloves
Apron or protective suit
Safety shoes
Fume extraction
Gooseneck Contact tube
Trigger
Consumables Contact tube support
The rollers are located in the reel and "push" the wire into the torch. A roller often accepts 2 sizes of wire (2 grooves).
Diffuser gas
Handle
Gooseneck
The wire reel contains the wire and is installed in the reel. - Type of metal e.g.: Steel - Wire diameter e.g.: ø 0.8 mm - Reel size e.g.: ø 300 mm (15 kg)
Ball joint
WELDING
SEMI-AUTOMATIC Abacus In order to obtain a good quality weld, the user must adjust his machine according to the type of joint and the thickness. TYPE OF JOINTS
SHEET METAL THICKNESS (mm)
WIRE DIAMETER (mm)
WIRE SPEED (m/min)
VOLTAGE (V)
INTENSITY (A)
WELDING SPEED (cm/min)
1 1.2 1.5 2 3 to 4 5 to 6
0.8 0.8 1 1 1 1
3 to 4 4 to 4.5 4 to 4.5 4.5 to 5 5.5 to 6.5 7
17.5 17.75 18 18.25 19.5 23
70 75 80 85 110 180
30 28 28 28 28 28
1 2 3 4 5 6
0.8 1 1 1 1 1
4.5 to 5 3 to 4 4 to 4.5 4.5 to 5.5 6 to 7 7 to 8
18 19 23 24 26.5 28
80 100 180 200 250 280
45 40 30 26 25 35
TOE TO TOE SET
E
ANGLE INTERIOR
On your MIG/MAG welding machine, there are two main parameters to set: wire speed and voltage. Depending on these two settings, the way the material is transferred can be different:
By short-circuit.
In large drops
• The material is deposited in small regular drops. • For welding thin materials and welding in position.
By axial spraying
• Deposition of the material in large drops. • For welding medium thickness sheets (hard facing)
• Deposition of the material by microdroplets. • For welding thicker sheets (5 to 15 mm).
Setting the wire speed Wire speed too high
The wire strikes the workpiece and prevents material from being deposited (weldbead).
Wire speed too slow
The material is not deposited correctly or the wire is welded to the contact tube.
For a good welding ... 1. To start your weld, press the trigger of the torch, the arc will start as soon as the wire touches the part to be welded. 2. As soon as the melt has reached the desired width, advance the torch. 3. At the end of the weld, release the trigger and hold for a few seconds to extend the gas protection and protect the weld from oxidation. Selecting the welding method
«push» method - the preheating is less strong - the cord is wider - penetration is less important
«drawn» method - the sheet is well preheated - the melt is very hot - the weldbead is curved but less wide - penetration is deep.
Method of movement
Linear movement
Sweeping motion
Used for most welds.
For a stronger weld.
WELDING
SEMI-AUTOMATIC Choosing the right MIG/MAG welding machine
Pulsed Inverter
Smooth inverter
Inverter Traditional
•
-
(A)
0.9 - 1.0
85 A
Ø 300
Cored wire (no gas)
Ø 200
Standard solid wire
Max intensity
Reel size (mm) Ø 100
Brazing
Alu
< 2.5 mm
Wire diameter
EASYMIG 110
< 2.5 mm
•
•
0.6 - 0.8
0.9 - 1.0
110 A
EASYMIG 130
0.8 to 3 mm
•
•
0.6 - 0.8
0.9 - 1.0
120 A
EASYMIG 140
0.8 to 3 mm
•
•
0.6 - 0.8
0.9 - 1.0
140 A
EASYMIG 150
0.8 to 3 mm
•
•
•
0.6 - 0.8
0.9 - 1.0
140 A
EASYMIG 160
0.8 to 3 mm
•
•
•
0.6 - 0.8
0.9 - 1.0
160 A
EASYMIG 160 XL
0.8 to 3 mm
•
•
•
0.6 - 0.8
0.9 - 1.0
160 A
EASYMIG 180-4 XL
0.8 to 3 mm
•
•
•
0.6 - 0.8
0.9 - 1.0
180 A
MULTIPEARL 210-2
0.8 to 6 mm
•
•
•
•
0.6 - 1.0
0.9 - 1.2
200 A
MULTIPEARL 210-4 XL
0.8 to 6 mm
•
•
•
•
0.6 - 1.0
0.9 - 1.2
200 A
MULTIPEARL 211-4
0.8 to 6 mm
•
•
•
•
0.6 - 1.0
0.9 - 1.2
200 A
MULTIWELD 160M
0.8 to 4 mm
•
•
•
0.6 - 0.8
0.9
160 A
MULTIWELD FV 220M-C
0.8 to 6 mm
•
•
•
0.6 - 1.2
0.9 - 1.2
220 A
MULTIWELD FV 220M
0.8 to 6 mm
•
•
•
0.6 - 1.2
0.9 - 1.2
220 A
MULTIWELD 250 T-C
0.8 to 8 mm
•
•
•
0.6 - 1.2
0.9 - 1.2
250 A
MULTIWELD 250T
0.8 to 8 mm
•
•
•
0.6 - 1.2
0.9 - 1.2
250 A
MULTIWELD 320 T-C
0.8 to 10 mm
•
•
•
0.6 - 1.2
0.9 - 1.2
320 A
MULTIWELD 320 T
0.8 to 10 mm
•
•
•
0.6 - 1.2
0.9 - 1.2
320 A
EXAGON 400 CC/CV + EXAFEED 4L
0.8 to 15 mm
•
•
•
0.6 - 1.6
0.9 - 2.4
400 A
NEOPULSE 220 C + XL
0.6 to 7 mm
•
•
•
•
0.6 - 1.2
0.9 - 1.2
220 A
NEOPULSE 320 C
0.6 to 12 mm
•
•
•
•
0.6 - 1.2
0.9 - 1.6
320 A
NEOPULSE 400 G + wire feeder
0.6 to 12 mm
•
•
•
•
0.6 - 1.6
0.9 - 2.4
400 A
NEOPULSE 500 G + wire feeder
0.6 to 15 mm
•
•
•
•
0.6 - 1.6
0.9 - 2.4
500 A
•
-
0.9 - 1.0
110 A
SMARTMIG 110
Traditional & synergic
thickness
Wire type Cored wire (no gas)
EASYMIG 85
Sheet
Steel/stainless steel
Tutorial video Multipearl
< 2.5 mm
SMARTMIG 142
1 to 3 mm
•
•
0.6 - 0.8
0.9 - 1.0
140 A
SMARTMIG 152
1 to 3.5 mm
•
•
•
0.6 - 0.8
0.9 - 1.0
140 A
SMARTMIG 162
1 to 4 mm
•
•
•
0.6 - 1.0
0.9 - 1.2
160 A
SMARTMIG 182
1 to 5 mm
•
•
•
0.6 - 1.0
0.9 - 1.2
180 A
SMARTMIG 183
1 to 5 mm
•
•
•
0.6 - 1.0
0.9 - 1.2
180 A
MONOGYS 200-2CS
1 to 5 mm
•
•
0.6 - 1.0
-
200 A
MONOGYS 250-4CS
1 to 8 mm
•
•
0.8 - 1.2
-
250 A
MONOGYS 320-4CS
1 to 10 mm
•
•
0.8 - 1.2
0.9 - 1.2
320 A
TRIMIG 200-4S
1 to 5 mm
•
•
0.6 - 1.0
-
200 A
TRIMIG 250-4S DV
1 to 8 mm
•
•
0.6 - 1.2
-
250 A
TRIMIG 300-4S
1 to 10 mm
•
•
0.6 - 1.2
0.9 - 1.2
300 A
PROMIG 400-4S
1 to 12 mm
•
•
0.6 - 1.6
-
350 A
PROMIG 400-4S DV WS
1 to 12 mm
•
•
0.6 - 1.6
-
350 A
PROMIG 400-4S DUO DV
1 to 12 mm
•
•
0.6 - 1.6
0.9 - 1.6
350 A
PROMIG 400G DV
1 to 12 mm
•
0.6 - 1.6
OPTION
350 A
PROMIG 400G DV WS
1 to 12 mm
•
•
0.6 - 1.6
0.9 - 1.6
350 A
MAGYS 400-4
1 to 12 mm
•
•
•
0.6 - 1.6
0.9 - 1.6
350 A
MAGYS 400 GR +WS-4R
1 to 12 mm
•
•
•
0.6 - 1.6
0.9 - 1.6
350 A
MAGYS 500 GR +WS-4R
1 to 15 mm
•
•
•
0.6 - 1.6
0.9 - 2.4
450 A
MAGYS 500 WS +WS-4L
1 to 15 mm
•
•
•
0.6 - 1.6
0.9 - 2.4
450 A
•
•
•