MIG welders are units that are of immense importance both in homes and industrial purposes. It uses an arc welding mechanism in welding of metals.

MIG welders use electrodes in cutting and merging of metals together. The electrodes/wires are of different types depending on the functionality of the unit that you’re using.

Notwithstanding, this equipment comes in different forms. Therefore, it’s paramount that users understand the features and know how to use the features. There is also a roller tension which is adjustable. The adjustability of this function affects solely the speed of the wire feed.

This has to be done before welding so as to make accurate precision, and it’s mostly done together with voltage. The performance is amazing. At the press of the trigger, the gases automatically flow and propel the electrode into high performance. The influence of this shielded gas is to aid users in making accurate precision.

However, the propensity of the motion of the electrode is determined by the regulation of the functions that a product consists. Aside from that, improper handling can lead to accidents.

In fact, researchers indicate that the falling of atomized flakes (UV rays) that escapes into the air on the epidermis during the process can lead to cancer or skin damage.

Therefore, that’s why it’s essential that users learn how to use a MIG welder so as to avoid mishaps. So, let’s find out the systematic manner that you can safely use a MIG welder.

8 Things to Consider about How to Use a MIG Welder:

1. Personal Preparation

2. Preparation of Workpiece

It’s very essential that one clean the surface of the workpiece before it’s welded. This would prevent users from prospective accidents and it aids one to make accurate precisions.

Also, have a clue on how you intend welding your workpiece. The three methods that you can practice are T-joint, butt-joint, and lap joint. However, before one begins to weld, one must ensure that no flammable object is left close-by.

In fact, it’s advisable that one choose a secluded region where is not windy so as to make a clean flawless work, especially while joining thick metals of 3/8” or aluminum. As a matter of fact, we’ll enjoin you to make the right choice while choosing an instrument.

3. Tips for Choosing Best Electrodes for Best Work While Welding

There are several modes that you can use a MIG welder for. The modes that you use it for depends on the nature of the workpiece that you’re working for.

The modes are short circuits, globular transfer, and spray transfer meanwhile the modes are used for thin metals, heavier metals, and hottest respectively.

Furthermore, for shield welding, you might want to choose between AWS ER703SS-3 and AWS ER703SS-6. The former is used generally for steel materials while the latter is used for rusty steel.

Notwithstanding, for thicker ones, you’d need E71TGX which seemly doesn’t require shield gases. As a matter of fact, they are used in a windy environment. Please note that those that use gas tanks don’t use flux-core although some possess both features.

4. Adjusting the Tensioner

During the pre-sets we enjoin you to maintain the position of the electrode so as to attain a regular precision. Also, make sure that you know the power supply mechanism that your unit operates with.

5. Flat Position

For flat welding, you’d have to position the MIG welder at the top of the base metal. There are 3 forms of welding that you can achieve with this: they are butt joint, T-joint, and Lap joint.

The categorization is based on the degree that base metals are positioned for welding. A butt joint is achieved when base metals are positioned in 180 degrees.

Meanwhile, the T-joint is achieved when base metal is arranged in 90 degrees while lap weld is known as fillet weld. Whenever you want to weld any of these, you’d have to position it “half-target”.

That is; for butt welding, position the spool gun at 90 degrees of the workpiece and at 45 degrees for T-joint while either 60 or 70 degree for lap joints.

6. Horizontal Position

Make sure that you master the voltage and the amperage that’s the best suit the work that you’re doing. And while you’re working on this position, the temperature of the welder has to be regulated within a range of 0 and 15 degrees.

Also, it’s expected that the tip of the MIG welder is preheated before it’s used so as to make penetration pretty easy.

7. Vertical Position

Albeit, provided you’re welding a material vertically, you’d have to regulate the temperature within the range of 10-15% from the angle used for flat position, why?

So as not to be disrupted by gravity. In fact, it’s advisable that one begins to weld from the tip of the workpiece to the nadir while welding a thin material while the inverse is the case for the thicker ones.

8. Overhead Position

Meanwhile, this position is of two major techniques, dragging and pushing. Whichever you imbibe while welding, the MIG welder would penetrate, but dragging is deeper and reliable for thick surfaces than thin surfaces.

Nonetheless, the travel speed must be high while the amperage and voltage must be reduced for perfect work-done.

Final Verdict

This is just how to use a MIG welder. The choice of an electrode is as important as the setups so it’s advisable that one practice the directions constantly. This information is alone to provide succor to your need. The information that’s provided is highly reliable and one can use it to operate all MIG welders.

When purchasing goods, one of the most frequently asked question is ‘what is the difference between these two?’ The welding field is no exception as most people keep enquiring about the difference between the different welders in an attempt to find out which one fits them most.

Welding is crucial and it is important to know the best method to use. Mig and Tig Welding are both methods of welding. Just like in any other field, each of them has advantages and disadvantages.

Understanding them both methods empowers you to choose intelligently the method that better suits you.

As you choose, it is important to understand how the two methods work. Look on those things every method wants in order to be effective. But we are going to look at them basically to identify the main differences and similarities between the two.

Differences between Mig and Tig Welding

The following are some of the key factors that you will look at in order to understand the differences between the two.

1. Procedure

Procedure is actually the key feature. This is the main difference between Mig and Tig welding. In Metal Inert Gas Welding, a continuous feeding wire is fed through the spool gun.

This is what creates the weld. On the other hand, in Tungsten Inert Gas Welding, a long welding rod is fed into the weld wet patch. Here, the user must fill the distinct filler with one hand while operating the torch with the other. This brings about the difference in terms of difficulty.  

2. Difficulty and Control

As cited above, Tig and Mig welding vary in terms of operation. Needless to say, Mig welding is far much easier since the wire is fed continuously.

Contrariwise, Tig requires the welder to hold the torch on one hand while holding the filler material on the other hand at the same time. This makes Mig Welding an ideal technique for but not limited to beginners.

In terms of control, Mig is for that reason easier to control as one only does it with one time. Tig is oppositely difficult to control as it demands timing, coordination of both hands and balancing without which the welder will deliver a poor weld that will not last long.

3. The thickness of the metal

While both Mig and Tig welding operates with a variety of metal types and gauges, Mig is more accommodating. It works best with an assortment of metals such as aluminum, stainless steel and even mild steel.

In as much as Tig can weld these metals too, it does well in the thin metals. So the thickness of a metal bring a big differences between the two methods of welding.

4. Power required

The amount of power required to weld differ in this processes. It bring much difference because the two methods use power differently.

Mig welders have an option of choosing between alternating current (AC) and direct current (DC) this allows you to choose the preferred current depending on the metal that you are welding which is actually a plus.

On the other hand, Mig uses direct current using a constant voltage.

5. Cost

We cannot finish without looking at the cost used for the two processes to work. In terms of cost Tig is much more expensive. First, the welding equipment is almost twice the price of a Mig welder in the same category.

The ideal arc characteristics and its ability to produce a very decent weld sacrifices its cost. The difference in price remains even as on moves to the machines with more power and more advanced features.

Secondly, as earlier mentioned, it is difficult to Tig Weld than to Mig weld. Subsequently, it is harder to train welders to Tig weld as it requires more time, skill and more expensive equipment.

6. Appearance of the weld

The appearance or body designs of the item welded can completely give a great picture on the process used in making the item.

Generally, Tig welding produces a cleaner weld. For this reason, it is used for welding ornaments since it is better-looking.

7. The shielding Gas

In Mig welding, the gas that is used to shield the arc from oxygen and the atmosphere is argon and Carbon (IV) Oxide (CO₂). As a matter of fact, Mig welders can use carbon (IV) Oxide and still deliver a perfect weld. Tig welding conversely uses mainly Argon.

8. Speed

From the foregoing discussion, it is clear that Mig is a faster method of welding compared to Tig welding. This makes Mig welding an ideal investment for the people that deal with large productions.

Tig, though highly detailed is slow and complex and there ideal for persons that are not dealing with very large productions.

Pros and Cons of Mig and Tig welding

Mig welding pros

Mig welding cons

Tig welding pros

Tig welding cons

Final Verdict

There are however myriad of differences between Metal Inert Gas welder and Tungsten Inert Gas Welding. They vary in a variety of parameters such as power, speed, thickness of the metal, cost, procedure, the appearance of the weld among others.

The two methods have their pros and cons and the success of the weld is dependent on so many factors including what you are welding, the quantity among others.

The decision on which one to purchase is consequently not an easy one. However, with the right understanding of the two methods, the decision on which method is better for you is an easier one.

Basically, Metal Inert Gas (MIG) welding as the word evince is a method of welding in which a gas is used to shield the weld pool from oxygen by displacing it.

Mig Welding without gas is a term used to refer to welding using a self-shielding Mig wire with flux core. In this case, a gas is produced from burning flux as the welding arc melts which in turn protects the weld.

This implies that the difference between Gasless Mig welder and a Mig welder is the source of the shielding gas that prevents oxidations.

How to use Mig Welder without gas

When you Mig weld without gas, you can do it perfectly in all conditions more especially in windy conditions. This is because the wire has got no flux inside hence creates the slag on top of the weld the moment it cools.

The slag basically protects weld puddle from this conditions and keeps away the atmospheric gases. Below are some of the basic processes to follow when you Mig welder without gas.

1^st Step

Start by ensuring that your safety is well considered. Whether you are a beginner or a professional welder, you agree with me that welding is a very demanding task that has many risks.

This include very high temperatures that may cause burns, Ultra-Violet (UV) light which is unsafe among others. This implies that for you to weld safely, you have to take all precautions and have all the protection equipment such as gloves, glasses, protective aprons etcetera.

This not only ensure that you are safe but also adds onto your comfort consequently making you very efficient.

2^nd Step

One of the known advantages of Flux-cored arc is that you can weld a dirty metal decently.  However, when one welds on a thoroughly cleaned metal, the difference is visible.

Cleaning the metal you are about to weld is pretty easy. It can simply be done using a brush or grinding. In short, just aim at removing foreign materials such as sand, soil and debris.

This also aids in removing all the trapped air resulting to a more decent weld. When grinding, the sparks produced should be directed in a safe direction to avoid burns.

3^rd Step

Decide on the machine you will be using to weld. Choose a more powerful welding unit that can handle thicker metal. There are different many different machines that can weld without gas.

Starting from a 115-volt welder and above is actually the best. This is the unit that can handle any metal up to an eight of the inch thick. This machines also have adequate preheating.

To most people, this is the most difficult process. While this may not be fully undeniable, it is however possible as long as you do all that is required patiently step by step.

You can then cut the piece of metal to use when welding. For you to be accurate, start by marking on the work piece where you want to cut. This is done using a soap stone.

Where a straight cut is required, marking should be done with the aid of a ruler or any straight object.  After marking, clamp the metal to prevent it from moving one cutting begins. Where you are cutting extensive length, use a long straight object as a guide.

Note: every successful cut begins with a scribe without which the chances of missing are very high.

4^th Step

Set up the cut pieces in the precise positions that you want to weld. This becomes very easy especially if you cut the pieces right as in step 4. Ensure that the pieces are firm and well-founded in their positions.

Select the right shielding gas. Metals such as aluminum requires the shielding gas of pure argon. This is actually in contrast with steel metal that uses a blend of carbon dioxide and argon.

Aluminum electrodes is mostly used when welding. As you use this electrode, ensure that thickness is the most important thing to consider. This is because there is extremely a narrow range to look at.

5^th Step

As earlier mentioned, whether it is Mig Welding without gas or simply Mig Welding, One requires a welding machine. Here, turn the welder on and adjust all the required settings. This depends on the metal that you want to weld, its thickness and type.

Some metals have an extremely generous welding parameters while others are very limited. This should be taken into consideration when setting the welder. Ensure that you check on all the requirements of the metal you want to weld.

Weld

Here, try as much as possible to be consistent. This helps you perfect the weld. If you are a beginner, take your time so that you are able to weld consistently as the smoke may in most cases shield you from seeing where exactly you are welding.

After welding, use a brush to remove the slag that may have formed to deliver a decent weld. Grinding softly enable you to deliver a neat weld.

Final Verdict

Gasless Mig welding is a simple process that is very ideal for but not limited to beginners. It is very convenient as it allows you to weld in windy conditions and saves on gas too.

It uses shielding gas and consumable wire electrode which continuously fed through the welding gun.. As we have seen it is important to keep the cable of the gun as straight as possible for the wire to feed properly.

Although it is a bit involving, patience with a lot of practice helps you to perfect the demanding task.

Cast Iron refers to a group of alloys of iron and carbon. The percentage of Carbon ranges from 2% to 4%. Cast Iron has a variety of uses which are as a result of its unique characteristics.

Although this outstanding parameters has made it very useful, it has on the other hand made it very difficult yet very necessary to weld especially due to brittle nature of some of the types. However, it is not impossible to weld. Below are guidelines on how to  MIG Weld Cast Iron.

How to Mig Weld Cast Iron

1. Metal Inert Gas (MIG) Welding

Metal Inert Gas (MIG) welding, also known as Gas Metal Arc Welding (GMAW) is a process by which an electric arc forms in the middle of an electrode and the metal. This causes the metal to melt which in turn causes them to join.

Mig welding is fast and undoubtedly produces a very high quality weld. The process is also simple and gives the best results as expected.

2. Gathering materials

As you prepare to Mig weld your cast iron. It is important to gather all the necessary materials you may need for the process to be effective.

Check to ensure you have things such as safety protective gears, welding machine and the metals and substances to be Mig welded.

Also check and ensure that the power source is available and it is enough to perform the entire process. Ensure that you have done proper setup of the welding machine and you take into consideration all the measurements required and adjusted all the adjustments.

3. 1^st Step

Safety is the first thing to look at before you start to Mig weld cast iron. Welding is a very demanding task that has so many risks involved. This is due to the heavy machines, blunt and sharp objects and even the very high temperatures and harmful gases involved.

Here, safety is key. Ensure that you are dressed in the right protective clothing such as gloves, glasses, welding jackets among others. This helps greatly reduce welding related accidents.

4. 2^nd Step

Cleaning the parts you are about to weld is a very important step regardless of the method of welding or even the type of the metal.

In as much as in some of the methods you get away with dirty surfaces, it is always imperative to clean as this results to an extremely eminent weld.

Remove the dirt thoroughly but carefully to ensure that the area you are about to weld has no foreign materials.

This helps remove the entrapped gas which ensures that the joint is stronger and will thus serve you for a longer period of time.

5. 3^rd Step

At this stage, you will attach the patch. (In this case, the patch can be the detached part of the work piece). Place it in between the integral part and ensure that it is firm enough and in a position that allows you to weld.

Placing the patch in the wrong position result to poor welding and results to a weak joint that only serves for a very short time. It may also alter the efficiency of the appliance that is being welded.

6. 4^th Step

You can now begin welding. When welding cast iron, temperature is key. For this reason, welding is done in short welds approximately 2.54 cm (0.025m) after each weld, it is important to wait for around 35 seconds (0.6 minutes).

This gives it ample time to cool thus preventing the temperatures from building up which in turn result to low productivity. The key point in this process is to keep it slow and low.

Cast iron does not stretch or deform. However, this sacrifices its resistance to cracking. Temperatures above 760⁰ C (1400 Fahrenheit) stresses the metal resulting to cracking.

7. 5^th Step

At this stage, you do studding. This involves drilling holes on the surface of the work piece. This allows you to use screws which makes the weld more successful. After this, weld the screws in place to ensure that the patch is held in place.

Studding results to a very strong weld. It is also cost efficient and provides fast firm attachment. This complements Mig welding.

8. Seal the cracks

Presence of cracks right after welding cast iron does not mean poor weld whatsoever. Cast iron is very delicate and it easily cracks. This implies that it is practically impossible not to find cracks after welding in as much as the right procedure was strictly followed.

Search for the cracks and seal them using a sealing compound for the joints to be water tight. This will in turn make them to last longer. After sealing all the cracks, you can then clean the machine and let the place be clean as it was before.

Final Verdict

Finally, there are other methods that are used to weld Cast Iron perfectly. This include using a nickel rod, using stick welder or even using an iron rod. This methods are conversely very difficult due to the nature of Cast Iron as earlier mentioned.

However, from the foregoing discussion, it is clear that Mig welding Cast Iron is not only much easier but also very convenient. It is also cost effective and most used method.

The weld lasts long and has a very high quality since slag is not entrapped and the arc is protected by the gas. This stress-free process is therefore ideal for but not limited to beginners.

The first thing that you’d want to do after purchasing a MIG welder is to find out how it can be coupled, right? If that’s the case with you, then you’re at the right place.

MIG welders use different power sources, mostly DC or AC, and users can decide whether to use a shield gas for the propelling of the electrodes with their unit or not to. However, this feature depends on the capability of the unit to use flux-core arc welding or not.

In a nutshell, products that have this feature optionally require gases. In addition, the fact that the structural pattern of each product is different makes it difficult for one to flawlessly describe how to assemble a MIG welder.

Notwithstanding, we’ll make sure that general tips on this subject are provided. Of course, with this in view, the subject will become comprehensible and easy to carry out.

All you just have to do is to check out the 8 points listed below.

8 Things to Consider about How to Set Up a MIG Welder:

1. Purchase the Right Product

This is just what you’d need to find out first, how? Some products are made in countries that don’t have English speaking as their ultimate language so you might find the illustration about its use “hectic” and incomprehensible.

Nonetheless, the best way to get this settled is to find out from the reviewers on available platforms whether the product can be used by a novice just like you. If your findings are positive, then you can proceed.

2. Read the Manual

The manual that comes with the delivery of a product is the best tutor. It’d instruct you better on how the product is set up and how to use the unit itself.

Irrespective of the size of the content that an instruction booklet consists, it’s still pretty useful. In fact, you’d come to find out how to open some intricate part of the unit. You might even see some diagrammatical depiction so as to make readers understand the instruction.

Howbeit, in case you find out that the product that you’ve purchased has deficient information in its manual, then you might want to consider this piece for quality information.

3. Identification of the Components

There are two types of MIG welder. The categorization is centered on the gas that’s used for them. You’d find them to be either aired or watered type.

The watered MIG welders are heavier and very difficult to manipulate unlike the former. You’d also find those that can be used for flux-cored arc welding.

Notwithstanding, here are the components that MIG welders have:

Nozzle: The nozzle is one of the essential parts. Operators can easily change the electrode at the tip of the unit. Nevertheless, it depends on the directions that are provided by the manufacturer.

Trigger: The trigger is the part of the MIG welder’s spool gun that the initiation of the welding takes place. In other words, it initiates the welding mechanism.

Lock: Locks are always found at the top of the spool gun, how, depending on the construction of the product. The lock helps one to hit a regular target.

Contact Tube: This component is found on the spool gun also. You would find it where it’s located if you can find it out from the manual that’s provided with the delivery of your product.

Clamp: The clamp clips the metal to considerable form. The clamp has to be connected to either of the ports that have depictions of charges as illustrated by the manufacturer while the spool gun is fixed to the other. Nonetheless, others to look out for is roller tension, and so on.

4. Assembling

5. Technical Setups

Make sure that you fix the loops to where they belong as instructed by the manufacturer of the product. You can simply find the tips around the body of the product or you might find it on the manual.

Whichever way, ensure that you determine the thickness of the metal before you dial the knob to the right “reading”.

It’s essential that you put this into consideration before you begin its use. However, you can find details about this from nominal users of the same product either via forums or any other online medium.

6. Ignition

Provided you’re using gases, then you’d have to opt for the gases that suit the project that you’re embarking on.

However, provided you’re using the flux-core arc welding mechanism then you’d have no need for tanks, why? Because the wires are good enough to be used in a windy environment.

Notwithstanding, you’d have to switch on the tank before you begin to work whenever you’re ready to work with MIG welder with gas tanks. However, do this discreetly so as to avoid accidents and other mishaps.

7. Safety Precautions

8. Repetition

We employ you to imbibe the steps that we’ve provided you on this platform. The systematic approach to the steps would make you become an expert in no time.

Final Verdict

This article has just explained how to set up a MIG welder. In summary, what one must put into consideration is the type that an individual is using.

Also, one must master the design of a product and know how they can be used. We just hope that our amiable readers would have the best fun setting up their units.