MIG/MAG welding, also known as gas metal arc welding, is a frequently used welding process that allows for high welding speeds.
There are two different types of this process:
✓Metal Inert Gas (MIG) welding: This process uses inert, or non-reactive, shielding gases such as argon, helium, or a mix of the two. The heat for welding is produced by forming an arc between a consumable metal electrode and the workpiece, creating a weld pool and fusing them together. The arc and weld pool are protected from the environment and contaminants by a shielding gas.
✓Metal Active Gas (MAG) welding: During this process, active shielding gases such as carbon dioxide (CO2) or oxygen (O2) are added to the carrier gas argon. It is also possible to use pure CO2 as a shielding gas for the weld pool. These gases can react with the filler metal transferring across the arc and the weld pool, affecting its chemistry and/or resulting mechanical properties.
MIG/MAG welding processes are very versatile and can be used in a range of sectors, including the metalworking industry, shipbuilding, steel and container construction, and the automotive industry. MIG welding is particularly suited to the non-ferrous metals aluminum, magnesium, copper, and titanium, while MAG welding is usually used to weld unalloyed, low-alloy, and high-alloy steels.
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What are the advantages of MIG/MAG welding?
MIG/MAG welding has several advantages:
➤High Deposition Rate: This process allows for a high deposition rate, which means more material can be welded in less time.
➤No Slag Formation: Unlike some other welding processes, MIG/MAG welding does not produce slag, so there’s no need for post-weld cleanup.
➤Simple Ignition of the Arc: The arc is easy to start, which makes the process more user-friendly.
➤Well-suited to Mechanized and Automated Welding: This process is easily automated, making it ideal for industrial applications.
➤High Welding Speeds: MIG/MAG welding allows for high welding speeds while still maintaining a high weld seam quality.
➤Well-suited to Out-of-position Welding and Welding in Difficult Positions: This process can be used in a variety of positions, making it versatile.
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➤Low Filler Metal Costs: The cost of filler metal for MIG/MAG welding is relatively low.
➤Increased Productivity: The process can be performed in numerous positions, and there’s no need for slag removal, which can increase productivity.
➤Easily Automated or Mechanized: MIG/MAG welding can be easily automated or mechanized, making it suitable for large-scale manufacturing processes.
➤High-Quality Welds: MIG welding offers high-quality welds with faster speed.
➤Pulsed MIG/MAG Welding: Pulsed MIG/MAG welding allows welding at higher deposition rates in all positions where dip or spray transfer are not applicable.
What are the disadvantages of MIG/MAG welding?
MIG/MAG welding, while advantageous in many ways, does have some disadvantages:
➤Outdoor or Drafty Conditions: Welding outdoors or in drafty halls is only possible under certain circumstances. Wind can disrupt the shielding gas, affecting the quality of the weld.
➤Rust and Humidity Sensitivity: This process is sensitive to rust and humidity, which can affect the quality of the weld.
➤Porosity and Lack of Fusion: There’s a risk of porosity and lack of fusion, which can weaken the weld.
➤Spattering: There’s a high risk of spattering, which can affect the appearance of the weld and may require additional cleanup.
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➤Weld Seam Quality: The quality of the weld seam may be lower than with TIG welding.
➤Limited Access: MIG/MAG welding may not be suitable for welding in difficult-to-reach areas.
➤High Initial Cost: The setup cost for MIG/MAG welding can be higher compared to other types of welding.
➤Skill Level: MIG/MAG welding requires a high level of skill, which can be a barrier for beginners.
How does it compare to TIG welding?
MIG/MAG and TIG welding are both commonly used welding processes, but they have some key differences:
➤Speed and Efficiency: MIG/MAG welding is generally faster and more efficient, especially for welding thicker materials. This makes it suitable for large parts and large production volumes. On the other hand, TIG welding is slower but can provide better control and accuracy.
➤Material Thickness: MIG/MAG welding is suitable for thick pieces, unlike TIG welding, which presents better results in thinner pieces.
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➤Quality and Appearance: TIG welding provides better control and accuracy, is suited for thinner materials, and produces tidier welds with minimal finishing required. MIG/MAG welding, while faster and more efficient, may not produce welds that are as precise, strong, or clean as those formed by TIG welding.
➤Ease of Use: MIG/MAG welding is considered easier to learn and perform.
➤Cost: The equipment and consumables for MIG/MAG welding are generally cheaper than those for TIG welding.