WELDING GAS METAL ARC WELDING (GMAW/MIG)

MECHANICAL ENGINEERING DEPARTMENT

REPORT MECHANICAL WORKSHOP PRACTICES 3 (JJ308)

WELDING GAS METAL ARC WELDING (MIG)

NAMA NO. MATRIX CLASS DATE LECTURE
MUHAMMAD SHAMMIR KHAIRUL MUZAMMIL BIN ABDUL JALIL 23DKM12F1022

DKM 3A 19/10/2013 EN. AMIRAFUAN BIN NORDIN

1. INTRODUCTION :

WELDING GAS METAL ARC WELDING (GMAW/MIG)

MIG is one of the easiest processes to learn. Most people can learn to run good beads with MIG in just a few hours. When did MIG start? MIG came about during World War II. It was developed to help produce weapons and equipment faster. It was then used in the postwar booming economy, mostly in shops and factories. What is MIG? MIG stands for metal inert gas. In stick welding the flux on the electrode melts and forms a gas to shield the puddle from the atmosphere. The atmosphere has hydrogen, nitrogen, oxygen, and other gases that will cause weld defects if allowed to get into the weld pool. In MIG, a spool of solid-steel wire is fed from the machine, through a liner, then out of a contact tip in the MIG gun. The contact tip is hot, or electrically charged, when the trigger is pulled and melts the wire for the weld puddle. This is accomplished in several ways. In short-circuit welding, small droplets of molten wire, heated when short-circuited, flow together to make a puddle as they touch the base metal.
2. OBJECTIVES:

Make sure students be able to : I. II. Do the process of welding such as Weld workpiece on flat position Weld workpiece with butt joint process Provide delegates with the necessary skills, knowledge and safe working practices to enable them to produce a range of welded joints in mild steel using the metal inert gas shielded welding process Become familiar with basic welding operations

III.

IV. V. VI.

Make an analysis based on work piece that being welding Explain the advantages of the metal inert gas (MIG) welding process. Describe the equipment, types of shielding gases, and electrodes used in the MIG welding process.

WELDING GAS METAL ARC WELDING (GMAW/MIG)

3. GAS METAL ARC WELDING THEORY

Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert gas (MIG) welding or metal active gas (MAG) welding, is a welding process in which an electric arc forms between a consumable wire electrode and the workpiece metal(s), which heats the workpiece metal(s), causing them to melt, and join. Along with the wire electrode, a shielding gas feeds through the welding gun, which shields the process from contaminants in the air. The process can be semi-automatic or automatic. A constant voltage, direct current power source is most commonly used with GMAW, but constant current systems, as well as alternating current, can be used. There are four primary methods of metal transfer in GMAW called : i. ii. iii. iv. Globular, Short-circuiting, Spray Pulsed-spray

Each of which has distinct properties and corresponding advantages and limitations. An arc is struck between a consumable electrode and the sheet metal to be welded. The consumable electrode is in the form of continuous filler metal. An inert gas surrounds the arc and shields it from the ambient to prevent oxidation.Carbon steels, low alloy steels, stainless steels, most aluminum alloys, zinc based copper alloys can be welded using this process.

4. TOOLS & EQUIPMENTS REQUIRED:

WELDING GAS METAL ARC WELDING (GMAW/MIG)

Figure 1 show the diagram of the MIGs tools and equipment required while table 1 is show the diagram name and their function.

2 1

3 5

4\4

10 8 9
FIGURE 1 TOOL AND EQUIPMENT OF MIG WELDING Table 1 TOOLS & EQUIPMENTS AND FUNCTION NO 1 TOOLS & EQUIPMENTS Gas Supply FUNCTION This is either 100% Argon or a mixture of CO2 and Argon. This gas shields the weld as it forms. Without the gas ,the welds will look brown, splattered and just generally not very nice. Open the main valve of the cylinder and make sure that there is some gas in it. Your gauges should be reading between 0 and 2500 PSI in the tank and the regulator should be set between 15 and 25 PSI depending on how you like to set things up and the type of welding torch you are using. When welding in areas with a draught you may need to run more gas pressure to avoid getting porosity in the weld. Once the wire passes through the rollers it is sent down a set of hoses which lead to the welding torch. The hoses carry the charged electrode and the argon gas. The earth clamp is the cathode (-) in the circuit and completes the circuit between the welder, the welding

Flowmeter/Regulator

Hoses

Earth Clamp

WELDING GAS METAL ARC WELDING (GMAW/MIG)

Mig Torch

Wire

7 8

Workpiece Anti Spatter Spray

torch and the project. It should either be clipped directly to the piece of metal being welding or onto a metal welding table like the one pictured below. The earth clamp must be making good contact with the piece being welded for it to work so be sure to grind off any rust or paint that may be preventing it from making a connection with your work The welding torch is the business end of things. It's where most of your attention will be directed during the welding process. The MIG torch consists of a trigger that controls the wire feed and the flow of electricity. The wire is guided by a replaceable copper tip that is made for each specific welder. Tips vary in size to fit whatever diameter wire you happen to be welding with. Most likely this part of the welder will already be set up for you. The outside of the tip of torch is covered by a metal shroud which protects the electrode and directs the flow of gas out the tip of the torch. The large spool of wire should be held on with a tension nut. The nut should be tight enough to keep the spool from unravelling so to avoids over-run (birds nesting) when trigger released, but not so tight that the rollers can't pull the wire from the spool. Mild steel workpiece that being used for differents type weld such as beadflow and butt joint. The heat on nozzle will evaporate water leaving behind a protective coating. Aqua-spat may be pre-applied to parts and will act as a rust preventative as long as the solution is not washed off the parts To trim long wires that being exit from the welding cup. To remove dust, and unwanted germs on the surface of the workpieces.

9 10

Pliers Wire Brush

WELDING GAS METAL ARC WELDING (GMAW/MIG)

8
5. SAFETY6EQUIPMENT : 7 equipment while Table 2 show the name of the Figure 2 is show the diagram of safety diagram and their function

Table 2 SAFETY EQUIPMENTS AND FUNCTION NO 1 SAFETY EQUIPMENTS Welding Helmet FUNCTION To protect the eyes, face and neck from flash burn, ultraviolet light, sparks, infrared light, and heat. Welding helmets are necessary to prevent arc eye, a painful condition where the cornea is inflamed. 5 which Welding helmets can also prevent retina burns, can lead to a loss of vision Are made to protect against sparks that will be flying off the steel you are welding. They are also there to 4 2 protect hands and arms from the heat of the welding of the machine, as well as the chemicals that the steel may have been treated with

Leather Gaunlet Style Gloves

Welding Apron

These aprons have an adjustable webbing strap around the neck and back with a heavy duty plastic buckle. The straps are sewn onto the apron with kevlar thread - sewn across and around for maximum durability. Many welders use a glove like this as it is strong, lasts a lifetime and provides good protection for them and

FIGURE 2 SAFETY EQUIPMENT OF MIG WELDING

WELDING GAS METAL ARC WELDING (GMAW/MIG)

4 5 6 7

Respirators First Aid Kit Leather Jacket Safety Boots

8 9 10 11

Appropriate Storage Of Gas Cylinder Check your cables Select electrode polarity: Set gas flow

12

Check tension

their clothes Protects against fumes and oxides Welder's first aid kit focuses on a wide range of injuries common to welders such as minor cuts, sprains, welder's arc and other common eye irritations. Protects against heat, fires and burns Notes: pants should not have cuffs, shirts should have flaps over pockets or be taped closed Protects against : electric shock heat burns fires Cylinder should be stored upright in a cool , wellventilated area,well away from any sources of ignition in order to prevent cylinders being exploded. Before striking an arc, check your welding equipment to make sure all of the cable connections are tight fitting and free of fraying or other damage MIG welding requires DC electrode positive, or reverse polarity. The polarity connections are usually found on the inside of the machine. Turn on the shielding gas and set the flow rate to 20 to 25 cubic feet per hour. If you suspect leaks in your gas hose, apply a soapy water solution and look for bubbles. If you spot a leak, discard the hose and install a new one. Too much or too little tension on either the drive rolls or the wire spool hub can lead to poor wire feeding performance. Adjust according to your owner's manual. Inspect consumables. Remove excess spatter from contact tubes, replace worn contact tips and liners and discard the wire if it appears rusty.

13

Inspect consumables

WELDING GAS METAL ARC WELDING (GMAW/MIG)

6. PROCEDURE: 6.1GAS METAL ARC WELDING PROJECT 1 (WELD WORKPIECES ON FLAT POSITION)

WELDING GAS METAL ARC WELDING (GMAW/MIG)

The workpiece has been brushed by wire brush in order to removed dust and unwanted germ in the surface of the workpiece.

Then , workpiece has been located on the table.

The workpiece has been clamped by earth clamp.

The welding cap was been sprayed by anti spatter spray

The M.I.G welding machine has been turned on the power.Then mig welding machine has been suit with suitable voltage, current and also resistance in order to get the good quality of welding.

The welding torch has been holded depend how student suitable with it.

WELDING GAS METAL ARC WELDING (GMAW/MIG)

WELDING GAS METAL ARC WELDING (GMAW/MIG)

The molten weld was produced on the corner of the workpiece.

The welding torch has being moved that used back and forth method until the end corner of the workpiece with straight line and suitable speed .

Finally the weld was done and wire brush is used again in order to make the bead more shined.

6.2 GAS METAL ARC WELDING PROJECT 2 (WELD WORKPIECES ON A SQUARE BUTT JOIN)

WELDING GAS METAL ARC WELDING (GMAW/MIG)

Two workpieces has been brushed by wire brush in order to removed dust and unwanted germ in the surface of the workpiece.

Then , workpieces has been located on the table that one of the workpiece was placed beside on of the another.

The workpiece has been clamped by earth clamp.

The welding cup was being replaced by new one because there is hole produced on the cup.Then welding cap was been sprayed by anti spatter spray

The M.I.G welding machine has been turned on the power.Then mig welding machine has been suit with suitable voltage, current and also resistance in order to get the good quality of welding.

The welding torch has been holded depend how student suitable with it.

WELDING GAS METAL ARC WELDING (GMAW/MIG)

WELDING GAS METAL ARC WELDING (GMAW/MIG)

The molten weld was produced on the both side of the corner of the two workpieces..

The welding torch was moved along the center of two workpieces with suitable speed ,angle and also power until the end of corner of both sides of the workpieces

Finally the weld was done and wire brush is used again in order to make the bead that produced between the two workpieces more shined.

7. RESULT

As a result , the project 1 was done by laying the spark weld along the stairght line on the workpiece but the bead flow that produced doesnt have a same wavelength and experiencing holes in the workpiece.While for the project 2 that is welding the two workpieces by using butt joint was done but the bead flow that produced was forming sputs and defects. Created burn hole also produced in the end of the two workpieces.

WELDING GAS METAL ARC WELDING (GMAW/MIG)

N O 1

Table 3 RESULT PRACTICAL FOR PROJECT 1 AND PROJECT 2 TYPE OF PICTURE OF RESULT PICTURE OF SPECIFICATION PRACTICAL PROJECT PROJECT GAS METAL ARC WELDING PROJECT 1 (WELD WORKPIECES ON FLAT POSITION)

GAS METAL ARC WELDING PROJECT 2 (WELD WORKPIECES ON A SQUARE BUTT JOIN)

There are too many differents as we can see on the both result of project 1 and project 2 compare with the specification project. There are many factors that we can determined it. The first one is if the project experiencing holes is because the power is turned up too high and its melting through the welds. While If the welds are forming in spurts, the wire speed or power settings are too low. The torch is feeding wire out of the tip, it's then making contact, and then melting and splattering without forming a proper weld. Futhermore, no or not enough shielding gas from the torch is surrounding the weld is one of the commons factor that effect on the project 1 and 2. You can tell when this happens because the weld will start splattering little balls of metal, and will turn nasty colours of brown and green you can also see air bubbles on top of the weld (porosity). Turn up the pressure on the gas and see if that helps.Weld is 8. CONCLUSION not penetrating. This is easy to tell as the weld will be weak and won't be fully joining two piece of metal on the project 2, it can be corrected by try more power and wire speed.While for weld burns a while right through your material,this is caused by welding with too much power and wee need tp simply turn down welding power . In order to make sure all the objective of this project being truly adapted to the students, get the perfect and also good quality of the weld we should follow all the tips that are given above because in order to get the best welding , students should do more exercises and always ask to their lecturer if them dont understand whay should they do , what should they start first and what shoul they end . To do welding process, student need to give 100% attention and stay

WELDING GAS METAL ARC WELDING (GMAW/MIG)

9. REFERENCE

Website i. ii. iii. iv. v. Edited by Einar Kramer, http://www.wikihow.com/Use-a-MIG-Welder Copyright 1999 American Metallurgical Consultants, http://www.weldingengineer.com/1mig.htm Mike Rogerss video on You Tube , http://www.youtube.com/watch? v=I9kiEdvuReM Kevin Carons Video on You Tube, http://www.youtube.com/watch?v=3ebx3hWu0Q Copyright 2013 BRW Technologies, http://www.brwtechnologies.com/Aqua_spat_welding_anti_spatter_spray_s/105. htm Powered by pay 4 letter, http://www.rtechwelding.co.uk/mig_welding_how_to_use_a_mig_welder_guide.php Millers Article, http://www.millerwelds.com/resources/articles/MIG-WeldingThe-Basics-for-Mild-Steel/

vi. vii.

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