Exploring MIG-MAG Welding

Introduction.

MIG-MAG welding is an electrical weld process in which, unlike welding with coated electrodes (process 111) and TIG welding (process 141), more than 1 parameter must be set in order to achieve the correct arc heat. This is more challenging for the welder as it is necessary to set up the power source, and for the welding specialist (supervisor?) who is required to complete the correct details in the WPS (welding procedure specification).

With welding processes 111 and 141, it is only necessary to determine and set up the correct strength of current. With MIG-MAG welding, both strength of current and voltage much be established, and the current strength connected? to the adjustable wire drive speed?. If an incorrect combination is selected, of which there are endless possibilities, this can lead to  welding of unacceptable quality.

The complexity is further increased by the additional choices to be made before welding commences, including:

  • type of protective gas;
  • weld wire - solid or filled wire;
  • filled wire type - metal, rutile or basic;
  • weld wire diameter;
  • weld position;
  • manual or synergic welding;
  • additional features of the weld power source.

The course ‘Exploring MIG-MAG Welding’ has been developed to help clarify the level of complexity required in order to  make the right choices and set the correct arc parameters.

‘Exploring MIG-MAG Welding’

In a lively and humorous way, students in this workshop are led by the trainer on a journey through the wonderful world of welding techniques, starting with the simple question: what exactly is electrical current?
Students are constantly challenged and put on the spot to answer the seemingly most simple questions, exploring the interconnections between everything that plays a role in welding. As these secrets are unraveled and logically explained, students will become able to master equipment and techniques which have previously baffled them.

Theory:
laws of electricity;
materials;
welding equipment;
gasses;
MIG-MAG welding;
relationship between arc-length and -voltage
MIG-MAG welding arc types;
other welding processes;
additional welding materials;
temperature control;
expansion and contraction;
crack formation;
welding errors and imperfections;
repair welding;
weld quality assurance  ;
standards;
weld certification and consistency ;
mechanisation and robotisation;
the welder ;

Workshop:
Making an ascending series of weld seams on a plate with different weld wire drive speeds? by using a synergic MIG-MAG welding power source to construct a synergic welding line from a specific welding programme.
Finding the ultimate parameter settings between current and voltage in a manual MIG-MAG welding power source.
Determining the appropriate pulse correction for a selected parameter setting for both current and voltage.
Determining the power increase and decrease for different arc lengths.
Determining the automatic arc length stabiliser for the MIG-MAG welding power source.
The influence of the torch angle.
The welder and relaxed MIG-MAG welding.
Dealing with welding fumes.

In addition, each student will receive a course folder with all course materials.