Mig welding. Manufacturing Process

MANUFACTURING PROCESS

Name : Zia ur Rehman

Roll # 12-MC-16

Presented to : Sir Shah Nawaz

MIG Welding

Metal inert gas welding: a

method of welding in which the filler metal wire supplies the electric

current to maintain the arc, which is shielded from the access of air

by an inert gas, usually argon

The "Metal" in Gas Metal Arc

Welding refers to the wire that is used to start the arc. It is shielded by

inert gas and the feeding wire also acts as the filler rod. MIG is fairly

easy to learn and use as it is a semi-automatic welding process.

Metal Inert Gas (MIG) welding,

also sometimes called Gas Metal Arc Welding (GMAW) is a

process that was developed in the 1940s for welding aluminum and

other non-ferrous metals. MIG welding is an automatic or semi-

automatic process in which a wire connected to a source of direct

current acts as an electrode to join two pieces of metal as it is

continuously passed through a welding gun. A flow of an inert gas,

originally argon, is also passed through the welding gun at the

same time as the wire electrode. This inert gas acts as a shield,

keeping airborne contaminants away from the weld zone.

How The Machine Works

The Welder : Inside the welder you will find a spool of

wire and a series of rollers that pushes the wire out to the

welding gun.. If the wire feed jams up for any reason (this

does happen from time to time) you will want to check

this part of the machine out.The large spool of wire should

be held on with a tension nut. The nut should be tight

enough to keep the spool from unraveling, but not so tight

that the rollers can't pull the wire from the spool.

Assuming you are

using a shielding gas with your MIG welder

there will be a tank of gas behind the MIG.

The tank is either 100% Argon or a mixture

of CO2 and Argon. This gas shields the

weld as it forms. Without the gas your welds

will look brown, splattered and just

generally not very nice. Open the main

valve of the tank and make sure that there is

some gas in the tank.

The Gas Tank :

The Welding Gun

The welding gun is the

business end of things. It's where most of your

attention will be directed during the welding

process. The gun 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.. The outside of the tip of gun is covered by a

ceramic or metal cup which protects the electrode

and directs the flow of gas out the tip of the gun.

During the MIG welding process, the

electrode melts within the arc and becomes deposited as filler material. The

shielding gas that is used prevents atmospheric contamination from atmospheric

and protects the weld during solidification. The shielding gas also assists with

stabilizing the arc which provides a smooth transfer of metal from the weld

wire to the molten weld pool.

Once your welder is set up and you have prepped your

piece of metal it's time to start focusing on the actual welding.If it's your first

time welding you might want to practice just running a bead before actually

welding two pieces of metal together. You can do this by taking a piece of scrap

metal and making a weld in a straight line of its surface.

Do this a couple of times before you start actually welding so that you can get a

feel for the process and figure out what wire speed and power settings you will

want to use.Every welder is different so you will have to figure these settings

out yourself. Too little power and you will have a splattered weld that won't

penetrate through your work piece. Too much power and you might melt right

through the metal entirely.

Once you've got your method tested

out a bit on some scrap, it's time to do the actual weld. In this photo I am doing

just a simple butt weld on some square stock. We've already ground down the

edges of the surfaces that are going to be welded so that the seem where they

meet makes a small "v". We are basically just taking the welder and making our

sewing motion across the top of the seem. It's ideal to weld from the bottom of

the stock up to the top, pushing the weld forward with the tip of the gun

If the weld is showing or you are

welding something that you want to look nice then you will most likely want to

grind down your weld and smooth it out. Slap a grinding wheel onto an angle

grinder and get started grinding on the weld.

Be careful as you approach the surface of the

original stock. You don't want to grind through your nice new weld or gouge

out a piece of the metal. Move the angle grinder around like you would a sander

so as not to heat up, or grind away any one spot of the metal too much. If you

see the metal get a blue tinge to it you are either pushing too hard with the

grinder or not moving the grinding wheel around enough. This is can happen

especially easily while grinding thing sheets of metal.

The neater your weld was the less grinding you

will have to do, and after you have spent a whole day grinding, you will see

why it's worth it to keep your welds neat in the first place. If you use a ton of

wire and made a mess of things it's ok, it just means that you might be grinding

for a while. If you had a neat simple weld though, then it shouldn't take too

long to clean things up.