Every welder wants their consumables to last as long as possible, however operators are often changing over parts and consumables frequently. Below are some helpful tips we have put together that can help your consumables last longer. As a result, it can positively affect productivity, quality and the bottom line.
The Heat Factor
Heat produced in the welding process can impact on the cleanliness and longevity of GMAW consumables. Processes like pulsed GMAW and/or higher amperage applications expose consumables to higher levels of heat, along with applications in which there is a large amount of reflective heat.
The hotter the consumables becomes while welding, the softer the material (usually copper or brass) becomes, resulting spatter to accumulate and premature failure.
It’s important to choose the best consumables for each application. High-amperage applications (above 300 amps) are often best for heavy-duty consumables because they have greater mass and are capable of dissipating the heat more readily. However, if the welding procedure indicates that the contact tip must be changed frequently, a standard-duty contact tip may suffice.
Proper Storage and Handling
Always keep GMAW consumables in their original packaging until they are ready for use. Opening them and placing them in a bin can lead to scratches or dents that allow spatter to adhere and will ultimately shorten the products’ life. Removing contact tips or diffusers from their packaging and storing them in open or dirty containers can cause dirt and oil to accumulate in the threads, which can impede them from properly seating together. Finally, welding operators should always use clean gloves when handling or replacing contact tips, nozzles and diffusers to prevent dirt, oil or other contaminants from adhering to them.
Establish and Maintain Good Connections
Installing GMAW consumables correctly and checking the connections can minimise the chance of poor conductivity, spatter accumulation or premature failure. Operators should follow the manufacturer’s suggestions for contact tip and gas diffuser installation. Never use wire cutters or side cutters — too much pressure from these tools can damage the inside diameter of the contact tip, which leads to poor welding performance and a shortened lifespan. Also these tools tend to scratch the surface of the consumables leaving marks that attract spatter.
Suggested practice – tighten the contact tip until it’s fully seated into the diffuser, then grip the contact tip with an appropriate tool as close to the base as possible, tightening it 1/4 to 1/2 turn past finger tight. This helps ensure a good connection that minimizes electrical resistance, overheating and damage to the consumables, as well as excessive spatter accumulation. Bernard consumables require no tools and can simply be installed by hand tightening the nozzle.
Tip: Inspect consumable connections regularly to ensure that they are secure.
Trim Liners Correctly
An improperly trimmed and installed liner can cause wire-feeding problems that lead to downtime. It can also affect the performance of consumables, how clean they stay and their longevity. Cutting a liner too short can cause the liner to be misaligned with or in the gas diffuser. The result is a welding wire that feeds off-center, leading to premature contact tip failure. Liners that are too short can lead to the build-up of debris between the liner and retaining head, which causes wire feeding issues and poor weld quality. A liner that’s too long can cause kinking that again leads to wire-feeding issues that shorten the life of the contact tip. Always make sure that to remove any burrs or sharp edges after cutting a liner to ensure smooth and consistent feeding of the welding wire.
Welding operators should always consult with the liner manufacturer’s recommendation for proper trimming and installation instructions. It’s also important to protect the liner from contaminants and handle it with clean hands or gloves, don’t let it drag on the ground.
Contact Tip Position and Nozzle Size
The position of the contact tip (extended or recessed) affects how long consumables last, along with how clean they stay. The farther the contact tip extends from the nozzle, the closer it is to the arc and the more prone it is to reflective heat. This can cause spatter accumulation and burnbacks. Using a recessed contact-tip-to-nozzle relationship when possible can minimise these problems and provide better shielding gas coverage at the same time.
For applications that require access into restricted areas, it is important to select a nozzle that provides that access, but isn’t tapered so much that it minimizes the space around the contact tip. If there isn’t enough space for shielding gas to flow out of the nozzle, it can cause the shielding gas to hit the work piece and begin jetting back and/or swirling. The result an increase in spatter. Also the smaller the bore size on the nozzle, the more prone it is to absorbing heat and having spatter adhere to it.
Other Considerations
As a general rule, companies should select the largest consumable that will work for the application and provide the necessary joint access. Larger consumables are able to resist heat and spatter build-up, and they often last longer as a result.
Selecting consumables with the right material for the application is important, too. For example, brass nozzles tend to resist spatter well and are good for lower-amperage applications (100 to 300 amps), whereas copper nozzles are better for high-amperage applications (above 300 amps) or for those with longer arc-on time.
When setting up a MIG welding machine, it’s important to consider gas versus gasless options and how to select the right type of inert gas supply for a MIG welding project.
The MIG welding process uses a gas to shield the filler metal and weld pool from reacting to any elements present in the surrounding environment.
However, MIG welding can also be performed as a gasless process which uses flux core wire without the need of shielding gases. The Flux Cored Wire MIG process, formally known as Flux Cored Arc Welding – Self Shielded (FCAW-SS) uses a specially designed cored wire protecting the weld pool from oxidation during the arc welding process.
The differences between gas and gasless for MIG welding
The main differences between MIG welding with a gas or gasless setup is gas provides a more stable, better-quality weld that produces less fumes and spatter. For a nice, clean weld on finer materials, gas MIG welding is preferable. While weld spatters are generally greater with a gasless process, some modern gasless wire can produce as nice as weld bead as gas MIG welding.
However, if you need to weld something in a hard-to-reach location, that is outdoors, a gasless setup is more efficient cost-wise, lighter, and portable for use. If cosmetics are not an issue, gasless MIG welding is more convenient.
Choosing the right MIG welding gas
When shopping for gas, you will want to look for products that are marketed specifically as MIG welding gas. If you are going to use gas for MIG welding, you will want to choose the correct gas for the metal you are working with.
Depending on the type of metal you are welding, the two most common gases used for MIG welding are pure argon (Ar) and an argon and carbon dioxide (Ar/CO2) gas blend. The primary difference between the two is that argon is an inert gas, while carbon dioxide is semi-inert.
For mild steel, argon and carbon dioxide (Ar/CO2) gas is recommended for a deeper penetrating weld with less spatter.
While for MIG welding aluminum, you will want to use pure argon (Ar) gas for a shallower, but thicker weld, with less spatter.
Power Welds offers a wide variety of MIG welding machines, products, and supplies for streamlining MIG welding processes on a variety of applications across different industries.
Stainless steel is a trendy material used for its anti-corrosive properties, durability, and beautiful finish. Its qualities make it perfect for food preparation utensils and appliances, medical equipment and devices, transporting substances that would corrode other materials, and so on.
If you have a project involving welding stainless steel, read on and research to obtain the best result for your task.
What Is Stainless Steel?
Stainless steel has the main advantage of not becoming rusty that easily, which is attributed to its chromium content (in between 10% and 30%). This iron-based alloy performs excellently at a wide range of temperatures, both hot and cold, which makes it so good for piping, medical devices, and instruments, lighting products, and at a large scale in buildings and other structures.
Amongst the other great qualities of stainless steel, we would like to mention that it’s easy to form and fabricate and it can be recycled, making it a sustainable material for wide uses.
Stainless steel might not be the easiest metal to weld because of its tendency to warp and the fact that you have to use a lower heat setting than you would with other metals.
Expectations. For an inexperienced welder, working with stainless steel might be frustrating at times, since it shows any little mistakes you make, affecting the end result. Also, as mentioned, it tends to warp when subjected to high heat, especially if it comes in thin sheets. It might also warp when cooling down.
Avoid Warping. To avoid the warping of the stainless steel, you can put a piece of copper behind the seam as you weld. This will cool down the area and prevent the weld from burning through on the other side. You can also take your time and weld in short segments, allowing the metal to cool off before moving to the next segment.
Prepare. Preparing the area and the stainless steel for the welding process also plays a big part in the success of your task, as certain precautions need to be taken first. You need to remember that stainless steel will rust if it’s exposed to particles as fine as dust from carbon steel, so make sure your materials, tools, and working area are completely clean before you start welding.
Types of Welding for Stainless Steel
In order to choose the best method to weld stainless steel, there are several factors to consider: the experience of the welder, the thickness of the stainless steel you are working with, how esthetically pleasing the end result must be, and what your budget and timeframe are.
Shielded metal arc welding (MIG Welder): Efficient in terms of both time and cost, MIG welding works with stainless steel as long as the final result doesn’t have to look flawless.
Gas tungsten arc welding (TIG Welder): This method is better for projects that require a lot of precision, such as ones involving smaller or intricate pieces, or those that will show the welding as part of the esthetic final result. TIG welding is slower and requires more experience, so don’t start before you test your skills first or before you are confident in your welding.
Stick welding: When choosing your welding rod or wire, make sure you select the same grade material or higher. Use stainless steel rods or, if you need to use another type of material, keep in mind that the weld can rust and protect it with primer or paint.
As you can see, you have several options to choose from, and the three common methods above should already be familiar to you. Go with TIG if you are working with thin sheets. If you are focusing on keeping the costs low, then you should go with spot welding. If you need advice on what would work best for you, ask an expert.
Other tips to take into account while welding stainless steel
How can you ensure best results when actually welding?
If TIG welding, go with a DCEN or DC electrode negative setting and a current with a ratio of 1 amp for every 1/1000-inch thickness of the metal.
If MIG welding, use the push technique. This approach lets you see what you are doing more clearly and produces less beading. Only use the pull technique when you need deeper penetration.
Hold your welding gun at a 90-degree angle with a travel angle of 5 -15 degrees. For T-joints and lap joints, try a greater angle of about 45-70 degrees.
Keep your work area clean, safe, and well ventilated.
Although welding stainless steel is a little more complicated than other welds, it can be done. You can even weld stainless steel to mild steel. Using the right equipment, managing your temperature, and getting the right filler material can produce a strong, durable weld.
Can I weld stainless steel?
It is possible to weld stainless steel with the correct tools and procedure, although it can be tricky. You need to be careful because it can get bent or cracked when it gets too hot. Even if it doesn’t crack, it can end up with scratches and marks. Keep the following in mind when welding stainless steel:
Different types of stainless steel need different welding techniques.
MIG and TIG welders are the best machines for welding stainless steel.
MIG is good for thicker pieces, while TIG is better for thinner ones.
You need a welding gun, wire, and temperature-checking device for welding.
In short, we recommend leaving welding stainless steel to the experts.
Do You Need Welding Supplies, Training, or Equipment?
There is quite a learning curve to welding stainless steel. As sturdy and flexible as this material is, welding can turn into a nuisance if you are not careful enough.
For all your welding needs, the Perfect Power Welding Supply team is at your service, providing high-quality welding supplies, classes, and support. If you have a project that involves welding stainless steel, don’t hesitate to contact us and ask for guidance, materials, and tools, as we have the expertise needed for the best result.
MIG (Metal Inert Gas) and TIG (Tungsten Inert Gas) welding are both methods of joining metals that employ shielding gas to protect the forming and solidifying joints from the atmosphere. These two processes differ in this manner from stick welding, where the burning flux surrounding the electrode provides a protective cloud over the weld area.
The three techniques are collectively known as arc welding and use the heat generated from electric arcs to liquefy metal. Stick welding is more formally called Shielded Metal Arc Welding, or SMAW, while MIG is known as Gas Metal Arc Welding or GMAW, and TIG is known as Gas Tungsten Arc Welding or GTAW. These three techniques progress toward more and more control and more and more precision, with corresponding increases in equipment costs. Stick welding is perhaps the crudest of the three but has tremendous application in structural steel work, heavy machinery fabrication, pipelining, construction equipment repair, digging/cutting tool resurfacing, and so on. A primary advantage of stick welding, besides its simplicity, is its usefulness in outdoor settings where the burning flux shielding is not disturbed by the wind.
This article briefly describes the distinction between the two inert gas welding methods, MIG Welder and TIG Welder.
There is some historical discussion as to whether the “M” in MIG stands for Metal, as is commonly accepted, or Mechanized, which it truly is. In this mechanized process, the electrode is fed automatically into the weld pool as the welder holds down a trigger. The welder need only move the MIG gun along the joint and the MIG machine feeds the welding wire while dispensing an atmosphere of inert gas over it. Let off the trigger and the process stops. There is no smoke from burning flux, no slag covering the joint after it solidifies, and no need for the welder to manually feed the electrode into the puddle as it is consumed – three characteristics associated with stick welding.
Of course, there is some complicated setup involved. Welding wire is sold on spools and is created not only in a range of diameters but in a range of materials just as stick welding electrodes are. The rollers that feed the welding wire from the spool up to the gun must be sized according to the wire diameter as must the tip of the gun where the wire comes out. Softer metals such as aluminum do not feed well from the machine up to the gun and so require a separate attachment that locates the spool feeder closer to the gun itself. The welder needs to select an appropriate amperage (as with stick welding) as well as a feed rate based on the size of the weld and the thickness of the material. Most of this information is codified so as to provide a starting point.
The selection of shielding gas and its flow rate is also important. Different gas mixes are used for different metals. Flow rates are adjusted based on travel speed, among other factors, and some gas must continue to flow onto the joint after the welding has ceased to insure coverage as the metal solidifies. A major advantage of MIG welding over stick welding is the efficiency of material use. The MIG welder can theoretically weld continuously until the spool runs out; the stick welder must grab a new stick every few inches and clean the slag off at the restart. Those little stub ends that the stick welder must throw away, an inch or two each time, can add up to significant material waste over the course of many welds.
Some claim that MIG welding is the easiest of the three processes to learn: if you can caulk you can MIG, they say. While that may be true in terms of one less factor to deal with, that of manually feeding the filler metal into the joint, there is quite a lot of technique and knowledge that goes into executing a sound MIG weld, as pretty as the weld itself may be. In reality, there are four types of MIG processes: short-circuit transfer, spray transfer, pulsed spray-transfer, and globular transfer.
MIG welding is used to weld steel, stainless steel, and aluminum. Stainless steel usually requires a 90%/7.5%/2.5% helium/argon/carbon dioxide mix while straight argon or argon/helium blends are used for welding aluminum.
The high melting point of tungsten allows it to produce an arc hot enough to melt steel without consuming itself. A separate filler rod is used to add material to the weld joint. TIG welding is thus a two-hand process and not mechanized, although a wire feeder may also be used. A footswitch is available to further complicate matters.
It is the footswitch that gives the welder minute control of what happens in the weld pool, or puddle. The amount of heat going into the metal can be varied by simply stepping on or letting off of the “gas,” controlling the amperage of the arc. This control allows for the joining of very thin metals—think beer can thin—without burn through. Likewise, with manual manipulation of the filler rod, the welder has very many variables under direct control. As with MIG, shielding gas flows out through the nozzle of the TIG torch. The torch itself requires cooling of some sort.
It is easy to understand why TIG is the most difficult of the three processes to learn. Tungsten electrodes need to be properly ground and maintained. Special techniques such as “walking the cup” may be employed to produce some strikingly beautiful welds. As with MIG welds, aesthetics only run skin deep. TIG welding is used to produce welds that are extremely clean, as might be appropriate to a piping system that handles highly purified chemicals.
TIG welding can be used to weld steel, stainless steel, aluminum, nickel alloys, magnesium, copper, brass, and bronze. Gas mixes similar to those used for MIG welding are employed.
Summary
This article presented a brief discussion of MIG and TIG welding. For more information on related products, consult our other guides or visit our specific welding equipment products.
Welding is a process used in fabrication for thousands of years. Different types of welding help fabricators forge swords, build ships, build furniture, and more. There are many kinds of welding, each with specific practical applications. When you start, you will find that some welding types are easier to learn, while other processes can take years to master. Different types of welding work indoors, while others are best applied outdoors. Read on to learn more about the types of welding and to determine which best suits your needs.
The Different Types of Welding MIG vs TIG vs Arc
What are the different types of welding?
There are many different types of welding for various experience levels and applications. You can determine which type of welding is right for you by examining your welding experience and what materials you would like to weld. While some welding types create clean beads and require minimal cleanup, other types produce larger welds that make more slag to clean up. Some welding types only work on ferrous metals, while others are more versatile. We’ve compiled a quick list of a few common types of welding and their pros and cons.
Type
Pros
Cons
MIG welding – Gas Metal Arc Welding (GMAW)
MIG is great for welding large and thick materials quickly. It is the most beginner-friendly type of welding.
MIG welds are not as precise, strong, or clean not as TIG welds. The workpiece materials must be completely clean of any rust or slag.
TIG welding – Gas Tungsten Arc Welding (GTAW)
TIG is highly precise and versatile, allowing you to join a wide range of small and thin materials. It is great for welding non-ferrous metals.
TIG welding is more difficult to learn, making it a slower process with longer lead times and greater production cost.
Stick Welding – Shielded Metal Arc Welding (SMAW)
Stick welding is very versatile, inexpensive to start, and easy to learn. It can be used on a variety of metal alloys.
Consumable electrodes have to be frequently replaced and slag must be chipped away after welding, making it a slower process.
Flux Welding – Cored Arc Welding (FCAW)
Flux welding does not use shielding gas, so it can be used outdoors and in windy conditions. It can also be used on a variety of metal alloys.
The filler material is more expensive, compared to other types of arc welding. It also generates more fumes and smoke than other types of arc welding.
Energy Beam Welding (EBW)
Energy beam welding can weld thick and thin materials and dissimilar metals with different melting points and conductivities. EBW is precise and grants the welder control over the process.
Materials shrink and cool after joining, which can lead to cracking and bending at the weld.
Atomic Hydrogen Welding (AHW)
Atomic hydrogen welding can reach temperatures up to 4000 °C, which can weld tungsten, the most refractory metal. Hydrogen prevents oxidation and contamination of the materials. This process does not require flux.
Atomic hydrogen welding is being replaced by gas metal arc welding because of the availability of inexpensive inert gases.
Oxy-acetylene Welding
An oxy-acetylene torch is lightweight, compact, and quiet.
Oxy-acetylene torches can easily cut through ferrous materials that are up to 8 inches thick. You can use oxy-acetylene gas to cut, braze, and weld steel.
Acetylene fuel is more expensive compared to other fuels.
Plasma Arc Welding
Plasma welding torches give you ample control over the arc and high-quality welds. Welds are clean, smooth, and strong.
Plasma welding equipment is expensive, making startup costs high. It is a more specialized welding process and requires more time initially to train.
MIG welding
Metal inert gas (MIG) welding is an arc welding process that uses a solid wire electrode to produce a weld. The electrode is fed into a welding gun and is heated. It is an easy type of welding for beginners to learn.
TIG welding
Tungsten inert gas (TIG) welding is an arc welding process that uses a non-consumable tungsten electrode to produce a weld. It is a precise form of welding, offering the welder control to adapt the amperage and gas flow. TIG welds are most successful on more delicate materials and can be used to weld both ferrous and non-ferrous metals.
Stick or Arc welding
Stick welding is a manual arc welding process that uses a consumable electrode covered with a flux to lay the weld. It produces strong welds and works well with thicker materials. It is a versatile welding process, is simple to set up the equipment, and is generally easy to learn.
Flux welding
Flux welding is a semi-automatic or automatic arc welding process that uses a continuously fed consumable electrode. The electrode contains a flux core that provides weld protection from the atmosphere, making it highly portable and versatile.
Plasma arc welding
Plasma arc welding forms an electric arc between a non-consumable electrode and the workpiece. The process has a high temperature and energy concentration, enabling the welder to make deep and narrow welds at high speeds.
Oxy-acetylene welding
Oxy-acetylene welding uses fuel gases and oxygen to weld or cut metals. The oxygen increases the temperature of the flame to allow localized melting of the workpiece material.
Which type of weld is the strongest?
No welding type is the strongest among all welding applications. The strongest weld depends on the type of metal, the material thickness, and the expected weight loading onto the weld. TIG welding produces the cleanest welds in routine applications because a larger amount of filler metal goes directly into the joint and produces less splatter. It is also ideal for thinner materials that require more precise welds. MIG welding provides the most consistent welds and is the easiest type of welding for beginners. Flux Welding creates the strongest welds in thicker materials. The flux core wire allows the weld to cool more slowly, which creates a more consistent and stable weld joint.
Which type of welding should you learn?
When determining the type of welding you should learn, you can plan the type of materials you would like to work with, the amount of time you have to learn, and the resources you have available. MIG welding is the most beginner-friendly type of welding. It is a faster process that is easy to learn and forgiving of mistakes. TIG welding is a slower process that requires more time to master and produces more precise welds on a variety of material types.
What types of welding can you learn at The Crucible?
The Crucible teaches beginning and advanced classes in four different kinds of welding: oxy-acetylene gas welding, arc or stick welding, MIG welding, and TIG welding. Start with a beginning class in MIG welding, or sample all four types in our Exploring Welding class. The Crucible also offers beginner and advanced-level TIG welding classes, which will introduce you to working with a variety of materials. In an ARC welding class, you will learn how to use an electric arc to create heat to melt and join metals. ARC welding is a great method for advanced joints and welding positions. The Crucible’s Oxy-Acetylene welding class teaches you to weld with heat produced by burning gases. Oxy-acetylene is one of the most versatile types of welding. You can use it to weld iron or steel, and also use heat to cut, braze, and weld metals. It comes in handy for removing rust or scale from metals, and for loosening corroded nuts and bolts.
Types of Welding FAQs
What type of welding is the best?
The type of welding that will work best for you depends on your experience, materials, and projects. MIG welding is generally the easiest to learn. TIG welding is a slower, more precise process that works with many different types of materials. ARC and Oxy-acetylene welding produce strong welds on thick materials and can operate outdoors and underwater.
What’s the difference between MIG and TIG welding?
MIG and TIG welding both use an arc to create heat and weld metals together; however, the difference between the two is the way the arc is used. MIG uses a wire welding electrode that constantly moves through the welding machine on a spool to generate heat. TIG uses a tungsten electrode that produces an electric arc between the torch and the materials.
What’s the easiest type of welding to learn?
MIG welding is generally the easiest type of welding for a beginner to learn. MIG welders use a feed wire that runs through the machine at a preselected speed. This makes the process relatively fast and produces consistent welds.
What’s the hardest type of welding to learn?
TIG welding is the hardest form of welding to learn for a variety of reasons. The process of TIG welding is slow and takes time to get used to as a beginner. A TIG welder requires a foot pedal to feed the electrode and control the variable amperage while maintaining a steady hand at the welding torch. This grants the welder more control over the process, but it can take more time to learn as a beginner.
MIG welding, also named Metal Inert Gas welding, is a versatile and widely used welding process that is ideal for various applications, especially when working with mild steel. Whether you’re a beginner looking to get started or an experienced welder looking to refine your skills, this article will provide you with a comprehensive guide to MIG welding for mild steel. We’ll cover the definition, tools and accessories, safety precautions, and some tips for MIG welding mild steel to help you achieve clean and strong welds.
MIG welding is a welding process that uses a consumable wire electrode to create an electric arc between the electrode and the workpiece. This arc generates the heat required to melt the wire and the base metal (in this case, mild steel), which then fuses together as it cools. A shielding gas, typically a mixture of argon and carbon dioxide, is used to protect the weld pool from contamination by the surrounding air, which can cause defects and weaken the weld.
Advantages of MIG Welding for Mild Steel.
Ease of Use: MIG welding is known for its simplicity, making it an excellent choice for beginners. The process is relatively easy to learn and can produce clean, consistent welds.
High Welding Speed: MIG welding allows for faster welding speeds compared to other processes like TIG welding, making it suitable for projects that require efficiency.
Versatility: Mig welding can weld a wide range of materials, but it is particularly well-suited for mild steel, which is commonly used in various applications.
Clean Welds: MIG welding produces minimal slag (the byproduct of the welding process), resulting in cleaner and more aesthetically pleasing welds.
What Welding Equipment and Materials Needed?
Before diving into MIG welding for mild steel, it’s essential to gather the necessary equipment and materials. Here’s a welding tool list of what you’ll need:
MIG welding machine: Choose a MIG welder suitable for your project’s requirements. Consider factors like amperage, duty cycle, and voltage.
Mild steel wire: Select the appropriate wire diameter for your project. Common choices for mild steel include 0.023, 0.030, and 0.035 inches.
Shielding gas: A mix of 75% argon and 25% carbon dioxide (CO2) is commonly used for MIG welding mild steel. Ensure your gas supply is sufficient for your project’s duration.
Welding helmet: A quality auto-darkening welding helmet is crucial for protecting your eyes from harmful UV rays and allowing you to see your work clearly.
Welding gloves: Invest in high-quality welding gloves to protect your hands from heat, sparks, and splatter.
Safety glasses: Wear safety glasses under your welding helmet for extra eye protection.
Welding jacket: A flame-resistant welding jacket will protect your upper body from sparks and heat.
Welding table or workbench: Having a stable surface to work on is essential for precise welding.
Clamps and magnets: These are helpful for holding your workpieces in place during welding.
Wire brush and chipping hammer: These tools are used to clean and prepare the welding surface.
Welding Safety Precautions
Welding safety should always be your top priority when MIG welding. Here are some crucial welding safety precautions to follow:
Wear appropriate safety gear: Ensure you have the right protective gear, including a welding helmet, gloves, safety glasses, and a welding jacket.
Welding in a well-ventilated area: Proper ventilation is essential to prevent inhaling harmful fumes and gases produced during welding.
Secure your workpiece: Use clamps or magnets to secure your workpiece firmly in place, preventing it from moving during welding.
Keep a fire extinguisher handy: Accidents can happen, so have a fire extinguisher nearby in case of sparks or fire.
Inspect welding equipment regularly: Check your welding equipment for any signs of damage or wear before starting a project. Make necessary repairs or replacements.
Avoid Welding on Coated or Painted Surfaces: Strip any coatings, paint, or rust from the surface you plan to weld to ensure a clean and strong connection.
Now that you have the necessary equipment and safety precautions in place, let’s walk through the MIG welding process for mild steel step by step:
Step 1: Prepare Your Work Area
Ensure you are working in a clean, clutter-free area with adequate ventilation. Set up your welding table or workbench, and make sure all your tools and equipment are within easy reach.
Step 2: Choose the Right Wire and Gas
Select the appropriate wire diameter and shielding gas for your project. For mild steel, a 75% argon and 25% CO2 mixture is commonly used. Check your MIG welder’s manual for specific recommendations.
Step 3: Prepare Your Welder
Follow your MIG welder’s user manual to set the correct voltage and wire feed speed based on your wire diameter and material thickness. Ensure the welder is properly grounded.
Step 4: Prepare Your Workpiece
Clean the surface of your mild steel workpiece using a wire brush or grinder to remove any rust, scale, or contaminants. Ensure that the metal is clean and free from paint or coatings.
Step 5: Position Your Workpiece
Secure your workpiece in place using clamps or magnets. Position it so that you have good access to the joint you plan to weld.
Step 6: Welding Technique
Hold the MIG gun at a 15-30 degree angle to the workpiece and maintain a consistent distance (typically 1/4 to 1/2 inch) between the gun nozzle and the work surface. Start the weld by pulling the trigger, creating an arc, and moving the gun in a smooth, steady motion along the joint.
Step 7: Welding the Joint
Begin welding at one end of the joint and move towards the other end. Ensure that the weld pool fully penetrates the workpiece, creating a strong and uniform bead. Pay close attention to the puddle, making sure it doesn’t get too large or too small.
Step 8: Welding Patterns
Experiment with different welding patterns, such as a straight line, zigzag, or weave, to achieve the desired bead appearance and strength. Practice on scrap metal to refine your technique.
Step 9: Pause and Restart
If you need to pause during welding, release the trigger but keep the gun in position. This prevents crater cracks from forming at the end of the weld. To restart, simply pull the trigger and continue welding.
Step 10: Finish and Inspect
Complete the weld by moving beyond the end of the joint to create a small crater. Inspect the weld for any defects, such as porosity, cracks, or incomplete fusion. If necessary, grind down any imperfections and re-weld the area.
Achieving clean and strong welds on mild steel requires practice and attention to detail. Here are some additional tips to help you improve your MIG welding skills:
Maintain a Steady Hand: Keep a steady hand while welding to produce uniform and consistent weld beads.
Control Your Travel Speed: Avoid moving too fast or too slow. Maintaining a consistent travel speed helps control the heat input and bead appearance.
Watch the Arc Length: Keep the arc length consistent. Too long of an arc can cause a spatter, while too short of an arc can lead to incomplete fusion.
Clean the Nozzle and Contact Tip: Regularly clean the MIG gun nozzle and contact tip to prevent spatter buildup, which can affect the weld quality.
Practice on Scrap Metal: Before tackling your main project, practice your welding technique on scrap pieces of mild steel to gain confidence and refine your skills.
Keep an Eye on Your Gas Flow: Ensure a consistent and adequate flow of shielding gas. Too much or too little gas can result in poor weld quality.
Stay Safe: Always adhere to safety precautions, and if you’re unsure about any aspect of welding, seek guidance from an experienced welder or instructor.
MIG welding is an excellent choice for welding mild steel, offering versatility, ease of use, and the ability to produce clean and strong welds. By following the steps outlined in this article and practicing your technique, you can become proficient in MIG welding and tackle a wide range of projects with confidence. Remember that safety should always be your top priority, so take the necessary precautions to protect yourself and those around you while welding. With dedication and practice, you’ll be able to create high-quality welds that meet the standards of any project.
“MIG” stands for “metal inert gas” and “TIG” stands for “tungsten inert gas.” With MIG welding, a powerful electrical current is generated through the torch and arcs through the consumable electrode, joining the metal together and reinforcing the joint with added material. The TIG welding process is similar, except the electrode in the torch is made of tungsten and not consumable. A secondary filler rod of consumable material is used to reinforce the weld.
mig vs tig
There are 7 key differences between MIG and TIG welding to keep in mind for your project:
MIG welding uses a DC (direct current) power source because it’s reliable and provides for less weld splatter or mistakes in the weld. DC is better for thinner materials and gives the welder more control over the welds.
TIG welding can use both DC and AC (alternating current) power sources. This versatility is important for more experienced welders as it allows welders to select a power source suited for the specific material being welded.
2. Metal selection
Most metals can be welded using both the MIG and TIG methods, but some metals are better welded using one method over the other.
Metals for MIG Welding
MIG is best suited for welding laser cut mild steel and cast iron. MIG welding does not produce the most aesthetic welds, but these metals are easy to work with and can handle further processing to make the welded joints look smooth and clean.
TIG is best suited for welding laser cut aluminum and stainless steel. TIG welding is far more precise than MIG welding, so is perfectly suited to these metals that need to be handled and joined with care to avoid warping.
3. Electrode
MIG Welding Electrode
As mentioned above, the electrode used in MIG welding is consumable. It is placed inside the torch and melts the metal to be joined with an electrical current. The electrode then bonds to the welded metal and reinforces the welds.
TIG Welding Electrode
The electrode used in TIG welding is made of tungsten and is not consumable. The tungsten rod merely delivers the electrical charge and a separate rod of filler material is held and melted to the welds.
4. Shield gas
MIG Welding Shield Gas
The most common blend of shield gas in MIG welding is argon and carbon dioxide. This blend is suited for thicker metals, although the gasses used are sometimes too light and susceptible to being carried off by a breeze or minimal movement, causing the welds to be left unprotected. Flux-core welding is a type of MIG welding which does not require a shield gas supply.
TIG Welding Shield Gas
The most common blend of shield gas in TIG welding is argon and nitrogen or helium, or just pure argon. The shield gas used in TIG welding prevents the electrode from overheating, and is heavier than oxygen so is more capable of protecting the welds from air bubbles and splatter.
5. Welding quality
MIG Welding Quality
MIG welds are strong and durable and best suited for high stress, heavy duty applications. It is difficult to create precise, aesthetic welds using MIG welding, but the durability in thick materials is unmatched.
TIG Welding Quality
It is easier to create small beads and precise, aesthetically pleasing welds with the TIG welding method. TIG welding is also stronger and better suited for thin metals with more delicate applications.
6. Speed
MIG Welding Speed
Since the welding torch feeds the filler rod automatically, MIG welding is typically much faster than TIG welding. MIG welding is the first choice for high production applications due to its speed.
TIG Welding Speed
Because the welder has to supply filler rod manually, TIG welding is simply not as fast as MIG welding. The tungsten electrode in TIG welders also overheats faster when air cooled so need to rest more often.
7. Cost
MIG Welding Cost
MIG welding units are lower cost than TIG welding units. There is significantly less prep work needed for MIG welding, and because it’s faster than TIG welding, overall it’s the more affordable option.
TIG Welding Cost
The precision found in TIG welding does come at a cost. TIG welding units are more expensive and the slower speed TIG welding requires makes it cost more overall to TIG weld rather than MIG weld.
FAQs
Is TIG better than MIG?
It is difficult to determine whether TIG is better than MIG, as it depends on a number of factors. TIG offers greater weld strength and better aesthetics if completed properly by a skilled welder but, if the welder is less skilled, MIG welding may be a better option for a quality weld. MIG welding is also a faster process than TIG welding, allowing for longer runs to be completed in less time. So, ultimately, TIG is better in some instances and MIG is better in others.
Is TIG welding harder than MIG?
TIG welding is typically seen as more difficult to master than MIG welding as it is a less automated process that requires greater precision.
Should I learn MIG or TIG welding?
While stick welding is often considered to be the best process for total beginners, MIG welding is a better place to start learning the basics over TIG welding. You should be able to produce acceptable welds much easier with MIG than with TIG.
How to choose the right process for your application?
The differences between the two welding techniques mean that it can be difficult to decide when to use MIG and when to use TIG welding. Each technique has its own advantages, which can act as a guide to which technique to choose…
1. When to use MIG:
Thicker materials – MIG is better suited for joining thicker stock
Long runs – The continuous wire feed of MIG welding means that it is better for longer runs, needing to stop and start less often to replace the filler material than with TIG welding, which means less chance of weld defects
Difficult positions – MIG is easier to use in difficult positions as it only requires the use of one hand
High productivity – MIG welding is better suited to high levels of productivity than TIG welding, which is a slower process
Less experienced welders – MIG is easier to learn than TIG, so is better suited to less experienced welders
2. When to use TIG:
Thinner materials – The precision and accuracy of TIG welding means that it is ideal for joining thin materials that may be susceptible to burn through or warping
Short runs – TIG welding is best suited to short runs
Shop or bench work – TIG is not an easy process to manage when out of position, so the best results are achieved in bench or shop work
Delicate or fine work – TIG welding is preferred when the look of the final weld is important. Visible pieces such as automotive restoration or artwork will look better with TIG welding, while the process also allows for better control to prevent warping or burning
Non-ferrous metals – Experienced welders will tend to turn to TIG welding for aluminium, copper, stainless steel and other exotic metals
Experienced welders – All of the advantages of TIG welding depend on having an experienced welder, without which it is better to opt for a simpler method, such as MIG welding
Conclusion
MIG welding uses a continuously-fed electrode wire and shielding gas via a hand-held torch. TIG welding uses a non-consumable tungsten electrode with a shielding gas fed through a supply line and a separate, hand held filler rod that is manually fed into the weld pool. TIG welding also uses a torch mounted control or a foot pedal to change the amperage. Both types of welding typically use different shielding gases too.
Neither MIG or TIG can be deemed ‘better’ than the other as they both have their own advantages and disadvantages depending on the situation.
MIG welding offers low cost, fast welds and is easy to learn, meaning that less experienced welders can put down good quality welds. TIG welding is much more difficult to master as well as being more expensive and slower. However, TIG welding can deliver a level of accuracy and aesthetic quality that can’t be matched by MIG welding. Where MIG welding is better for thicker materials, TIG welding is preferred for thinner materials or more delicate jobs.
For Mig Welding aluminum…..You most often need a spool gun.
In this video, you can see that when mig welding aluminum, the weld puddle is pushed and not pulled. You can also notice the cleaning action of the arc around the edges of the weld puddle that breaks up the aluminum oxide and allows the puddle to wet in to the base metal. There are several aluminum mig welding techniques that work ok, but the one used in the video is just a slow steady motion.
For 1/8″ thick aluminum, unless you have the machine set just right, the slow steady bead just builds up too much heat because by the time you reach the edge of the metal, its really too hot and leaves a huge crater.
Another thing to learn from this video about aluminum mig welding is that it uses what is known as “spray transfer”.
Can you See the tip of the wire? It never goes into the puddle. Fine little droplets of metal “spray” into the weld. When you mig weld steel with “short circuit transfer” the wire actually fuses into the puddle and then arcs back many times a second and makes that bacon frying sound.
You do not want to hear a bacon frying sound when mig welding aluminum. IF you do, you have too much wire speed.
Another technique that I like better is to use kind of a step and pause technique where you hitch ahead quickly about a quarter inch and then pause…to the tune of about once every second.
So it goes like this. move ahead and pause…thousand one…move ahead and pause…thousand two.. This step and pause welding technique puts ripples in the weld like a tig weld. Almost like a stack of dimes. Another benefit is it seems to build up less heat by moving quicker.
The picture below is of a weld that was done using a step and pause welding technique with the spool gun.
The best way I have found to figure out the voltage and wire feed speed settings is to go to powerwelds.com and use their weld calculator .
Select process, material type and thickness. For 1/8″ thick aluminum, the lowest recommended setting for 3/64″ wire was 21 volts and 240 inches per minute.
That will only get you started and it is a good starting point…since every machine is a little bit different, tweaking the machine while playing with some scrap aluminum will get you even better results.
More Tips for Spool Gun Mig Aluminum Welding
“spool guns make me feel powerful!.. “
Aluminum wire is much softer than steel and is hard to feed very far thru a liner. That is the reason for spool guns. With a spool gun, the wire only has toe fed for a few inches. Whereas with a conventional mig setup, the liner is usually about 8-10 feet long. Trying to push soft aluminum wire thru a cable that long is challenging and mostly just not doable. The spool gun is the way to go. 1 pound spools of aluminum wire are loaded into a small gun that resembles a Tommy gun gun from old gangster movies. The spool gun is slightly less maneuverable than a conventional mig gun but the trade off is worth it in being able to consistently feed aluminum wire without bird nesting every few minutes.
100 % argon gas is usually the gas of choice but mixtures like 50/50 argon/helium can be helpful for welding thick sections.Make sure the polarity is connected properly. mig welding aluminum requires reverse polarity. Another way of saying reverse polarity is Direct current electrode positive or DCEP. The same polarity is used for welding steel with bare wire but since mig machines can be used for self shielded flux core wire also and some of those wires require using DCEN or Straight polarity, It is a good idea to check the polarity setup just to be sure.
The 1 pound spools shown in this welding video are available in either 4043 or 5356 alloy and other alloys too, but these 2 are the most commonly used. 5356 is a bit stiffer and is easier to feed. It is commonly used for mig welding 5052 aluminum. But the 4043 wets out better and generally gets less porosity. 5356 is also slightly stronger.
There are lots of considerations when choosing and there is a filler metal chart you can download at this link….. That has some valuable tips for choosing welding wire.
In the second video, the suggestion for setting wire tension is excellent. Trying to weld with not enough wire tension will cause burn backs and lots of cursing. Set the tension tight enough but not too tight. Too tight and the drive rollers will mash the wire and cause other problems.
Some important tips for mig welding aluminum:
1. Push dont pull. Pushing works much better whenever you can… But we both know that sometimes you just gotta do what you gotta do. Pulling the weld will cause it to be sooty but its not the end of the world. A stainless brush will remove the soot.
2. when setting the wire feed speed, start out high and then adjust lower. You will save lots of tips this way, trust me on this.
3. dont try to get the bacon frying sound like with steel, if you are getting this sound, your wire feed is a little to high. you are looking for a high pitched humm.
4. always snip the wire in between welding. this will save many tips
5. keep the stickout to around 3/4″ and you will save many tips
6. keep a new pack of tips in your toolbox cause… damn! – mig welding aluminum , even on a good day , goes thru some tips.
It is possible to mig weld aluminum without a spool gun. I used to work in a shop that did this. A short mig cable, a teflon liner, and a softer tension spring allowed us to weld pretty well. The trick was to angle the mig gun to that about an inch of wire fed out before it contacted the weld area. Then you could change to a normal welding angle. If we didnt do this, we got a lot of burnbacks because the mig machine did not have any run out or wire feed delay features.
To effectively weld stainless steel with tungsten inert gas welding process, it is important to consider carbide precipitation.
TIG Weld Stainless Steel: Carbide Precipitation
What is Carbide Precipitation? Carbide precipitation is said to occur when the chromium and carbon in 300 series stainless steels are drawn out of the microstructure and react with atmospheric gases. It occurs between 800°F – 1650°F (426°C – 899 °). So, one must aim to keep the metal below this temperature range. Alternatively, the aim should be to keep the metal under an inert gas envelope when it is in the aforementioned temperature range.
Most annealed austenitic stainless steels such as 304 have a characteristic to undergo this microstructural change. When the metal is exposed to the temperature range of 800°F – 1650°F (426°C – 899 °), the carbon and chromium diffuse out of the crystal structure and form chromium carbides. This chromium carbide precipitates out of the solid solution and settles at the grain boundaries.
The speed with which the chromium carbide precipitates depends on several factors. The temperature of the metal is one factor. The rate of carbide formation peaks at about 1200°F (648°C). At the outer limits of the range 800°F – 1650°F (426°C – 899 °), the rate of formation of carbide falls to almost zero.
Another factor is the time of exposure of the metal to the high temperature. Understandably, the higher the exposure time, the more is the amount of carbide precipitation.
The third most important factor is the amount of carbon present in the microstructure. A higher percentage of carbon means that a higher amount of carbide formation will occur. This is why, low carbon content is a desired feature in austenitic stainless steels.
Especially, when a part is envisaged to serve in a a high corrosive medium, it is preferable to have a low amount of carbon in the filler metal to be used for making the weld. For example, ER308 is an ordinary stainless steel filler metal grade, containing carbon up to 0.08%. However, ER308L is another grade in which the composition is the same as the ER308, but the carbon content is limited to 0.03%. The ‘L’ in the filler classification designation indicates that it is a low-carbon filler.
How is the formation of chromium carbide harmful? Well, it reduces the amount of chromium available to fight off the corrosion.
Heat And Travel Speed
Generally speaking, there are three factors in carbide precipitation: heat input in the welding, travel speed, and effectiveness of shielding gas.
A high input in the welding process causes the weld metal to cool slowly, thus increasing the chances of weld metal’s exposure to a carbide-inducing temperature range of 800°F – 1650°F (426°C – 899 °). Hence high heat input is not desirable in stainless steel welding.
Travel speed is a factor that indirectly affects the heat input. A very low travel speed means high heat input per unit length of the weld. High heat input, as we saw above, is an invitation to carbide formation. So, very low travel speeds should be avoided in stainless steel welding.
How to TIG Weld Stainless Steel Effectively-Preventing Carbide Precipitation
The third factor is the effectiveness of shielding gas. If the coverage of the shielding gas is inadequate, it causes more exposure of the hot weld metal to atmospheric gases. This accelerates the carbide formation.
Flux Cored Arc Welding (FCAW) is an arc welding technique that involves creating an arc between a continuous tubular filler metal electrode and the weld pool.
Flux-cored arc welding (FCAW or FCA) is a type of semi-automatic or automatic arc welding. A continuously-fed consumable tubular electrode carrying a flux and a constant-voltage or, less typically, a constant-current welding power source are required for FCAW.
The approach involves shielding gas generated by a flux enclosed within the tubular electrode (a trade name is inner-shield), with or without additional shielding from an outside supplied gas.
Sometimes an externally provided shielding gas is utilized, but more often than not, the flux itself is depended on to generate the necessary protection from the atmosphere, creating both gaseous and liquid slag to protect the weld.
10 Main Flux Cored Arc Welding Advantages and Disadvantages
10 Main Flux Cored Arc Welding Advantages and Disadvantages
Flux core welding is a versatile method of welding that also super popular and versatile. I wrote this guide describing in full detail the pros and cons of flux core welding. This guide should also help you decide whether flux core welding is right for you, how to get started, and what to expect when starting up. So what are the pros and cons of flux core welding?
Several pros to flux core welding include portability, ease of use, versatility, usability outdoors,and the ability to weld through rust. The cons of flux core welding include the cost of the electrodes, the appearance of the weld bead, spatter, and slag inclusions to name a couple.
Is Flux Core Welding Any Good?
Flux Core Welding, often abbreviated as FCAW, involves the use of a welding wire that is similar in many ways to Metal Inert Gas (MIG) welding except for the fact it includes a flux-cored compound within the wire that has the capability to remove the need for shielding gas.
As for the question of whether this welding method is any good, the answer is yes, provided that the weld bead is being laid down in the recommended circumstances, usually on thicker metals as will be discussed later in this article.
The Flux-cored welder is the field worker’s best friend because they are easy to move from site to site. They are also easy and straight-forward to operate when compared to stick welding. These machines can plug into the standard 120V power system in your home. Since a shielding gas is not needed, you can also use this method to weld in just about any type of weather.
As will also be discussed in further detail later, this welder is also one of the best systems for welding galvanized steel. This is because MIG welding is known for being nearly impossible to weld galvanized steel with because of issues with porosity.
One of the few downsides to this technology is the effort it takes to clean up the slag that is a by-product of the welding process. Fortunately, there are ways to mitigate these complaints that will be discussed in further detail below.
Pros of Flux Core Welding
There are several advantages to using flux core welding over other welding types, such as MIG welding. Learning flux core welding will provide you with the opportunity to weld a variety of materials both indoors and outdoors.
Flux Core Welding Can Easily Be Done Outdoors
Shielding gas is of utmost importance in Metal Inert Gas (MIG) Welding in order to keep the molten weld pool from oxygen, nitrogen and hydrogen in the atmosphere. If the weld pool reacts with these elements, it will become subject to failure from porosity.
Other reasons why you need to use shielding gases when welding includes the need to:
Prevent excessive splatter
Keep the arc stable
Control the weld penetration into the base metal
While the solid wires used in MIG welding require shielding gases, flux core wires do not require the use of shielding gases. The mechanics behind this capability will be discussed later in further detail later in this article.
The upshot of this is that flux core wires are popular amongst those who frequently have to repair metal equipment outdoors. Flux core welding is popular at construction sites, in shipyards and in the farm field.
Cost & Energy Savings
Flux-cored wires will cost at least a little more than a solid wire of the same size. You can see this by comparing the prices of the same-sized wire online.
This is not always apparent because there are many more factors to consider than whether or not the wire requires a shielding gas. Wires of the same size may serve different uses depending upon their chemical composition. There are wires made of premium materials that will also cost more.
Still, it has been suggested that you can save quite a bit of money by making the switch to gasless flux core wires, if you haven’t done so already. You will begin to really notice the cost savings once you become fully operational.
Depending upon the application, flux core wires can lay down a weld bead at a faster travel speed and with increased deposition rates.
A flux core electrode is capable of depositing up to 25 pounds of wire per hour. A MIG electrode, deposits 8 pounds of wire per hour when it is performing at maximum efficiency.
This affects your operating costs because you may have to consume more energy to deposit a pound of solid wire than you would with a flux core wire. Energy savings are perhaps most pronounced when you are welding in position and when you are welding outdoors.
Ability to Weld Rusty Materials
You will find that flux core welding electrodes are much less fussy than solid wire electrodes when it comes to being able to weld metals that have become rusted or otherwise dirtied.
Gas-shielded electrodes usually only perform adequately on base metals that are clean. The presence of extensive rusting and milling is a death-knell of sorts to weld quality. This is because gas-welding through such contaminants can contribute to excess porosity in the weld bead, enhancing the risk of this weld failing.
Self-shielding flux electrodes, on the other hand, can effectively weld through rust and still produce a quality weld bead. A rusty or scaled surface will not contaminate the weld because the flux contained within the wire is more forgiving of the base metal than a solid wire used in conjunction with a shielding gas would be.
Flux Core Welding Easy to Learn
Flux core welding holds a reputation for being easier to learn.
flux core welding is easier to learn than Stick Welding and TIG Welding. The skill level required to master Flux Core Welding is equivalent to that of MIG Welding.
Flux Core Welding/MIG Welding Machines Are Versatile
You can use the same small welding machine to perform both MIG and flux core welding. The machine can run off 115V electricity that you can get from your home and this welding machine is diverse in the number of purposes that it can serve.
Flux core welding can be used to weld all of the most common metals:
Carbon steel
Stainless steel
Aluminum
This makes the flux core welder ideal for home shops and farms. You also don’t have to worry about hauling around a box of electrodes, since the welding gun is fed by a continuous loop of welding wire. The spools vary in size, with the largest of spoils being large enough to fit in a barrel.
Portability
Once you drop the gas tanks, the MIG welding machines can be moved from one location to the next with ease. MIG welding machines will typically weigh just under 40 pounds if you are going with the welders marketed towards DIYers.
FC-120 Gasless Flux Cored Wire Inverter Welding Machine Welds up to 1/8 in. mild steel.
Plugs into household 220V, 20 amp outlet
One year warranty on parts and labor.
Easy to set even for novice users
Compact, portable and lightweight
Once you put together all your equipment, including the spool of flux wire, it won’t weigh much more than that. And without having to lug around cylinders of gas, you can easily transport the machine to make emergency repairs on construction or farming equipment.
Cons of Flux Core Welding
There are some drawbacks to flux core welding. For one thing, the electrode itself is more expensive than a solid wire electrode. You will also find that it produces more slag at the weld zone than most other electrodes do.
General Repairs
Pipelines
Shipbuilding
Manufacturing
Underwater welding
General Repairs
Flux core welding wires allow for greater penetration of base metals, as compared to other welding techniques. It also allows for greater deposition rates.
FCAW welding, whether self-shielded or gas-shielded, is really best-suited for welding thick materials that are at least 20-gauge in thickness. Examples of such materials include stainless steel, carbon steel, low-alloy steels, cast iron, and high nickel alloys.
What Is the Best All-Around Flux Core Welding Wire?
One of the most popular flux core welding wires is the E71T-GS. This is a self-shielding flux core wire that can be used in all positions. It is commonly utilized in auto body repair, farming equipment, tanks, and non-structural frames.
This wire is suitable for welding:
Thin carbon steels and carbon-manganese steel
Galvanized steels
General Field Repairs
Lap & Fillet Welds on thin gauge materials
he E71T-GS produces a low amount of splatter and it is easy to remove slag from the welded piece. It is tailor-made for routine repairs due to the low penetration of its arc into the base metal. The self-shielding characteristics make it an ideal welding wire for performing field repairs on construction and farming equipment.
This welding wire is also a favorite amongst home workshop welders because it handles like a dream on the 110-volt welding machines that are so often the centerpieces of DIY welding operations.
A Flux Core Wire Well-Suited for Stainless Steel
MIG welding is a welding technique that is commonly used to weld stainless steel. The ER 308L series wire is the most commonly used to weld most stainless steels. High-grade stainless steels are welded with the ER 316L series welding wires and the ER 309L series is used for the welding of stainless steel to other pieces of steel.
Generally, gas-shielded MIG welding wires are used to weld stainless steel pieces with mixtures of Argon and Carbon Dioxide used in the shielding gas. You may also find self-shielding flux core wires useful for welding stainless steel pieces.
The Blue Demon 308LFC-O flux core wire presents welders with the opportunity to weld stainless steel pieces without having to use any shielding gas. It can be used in the flat and horizontal welding positions and is compatible with DC+ (direct current positive).
It can be used for welding 300 series stainless steel up to 308L stainless steel. The 300 series stainless steels are commonly used in the automotive and construction industries. The 308LFC-O flux core wire can also be used to weld 430 series stainless steel.
Flux Core Can Weld Galvanized Steel
Flux core wires are capable of being used to weld galvanized steel pieces, while your typical solid MIG wires cannot do so. The ingredients in flux core wires enable them to successfully weld galvanized steel.
If you are planning on welding galvanized steel, you will want to pay special attention to the specific flux core wire you choose. Some flux core wire types are specifically designed for being compatible with galvanized steel.
The E71T-11 is the recommended flux core wire for welding galvanized steel pieces. It also works well with thin-gauge mild steels.
Is MIG Welding Better Than Flux Core?
Flux core welding is a lot more convenient than MIG welding because you do not need to use a shielding gas to keep the weld bead stable. Flux core welding is surely the preferred method when welding outdoors. There are circumstances in which MIG welding is the more suitable method.
One method is not necessarily better than the other but there are circumstances in which you may find one solid wire MIG welding more suitable than flux core welding.
Circumstances in which MIG welding may be the way to go:
If the metal that you are welding is less than 3/16” in thickness
If creating a weld with a clean finish is of importance to you
You are looking to lay down a weld bead that you will be able to easily paint over without having to remove excess slag
It can be nearly impossible to use MIG welding wires to weld galvanized steel.
You will find that flux-cored wires are significantly more effective for welding galvanized steel. Nearly every piece of metal that was designed to be kept outdoors, including chain link fence, is galvanized.
Flux core wires are able to successfully weld galvanized pieces because of the chemical composition of the flux. Scavengers and fluxing agents are able to refine the weld. They help to prevent the porosity and cracking issues that are observed when a piece of galvanized metal is welded using a MIG wire.
Is TIG Welding Better Than Flux Core?
TIG stands for Tungsten Inert Gas, a welding process that is officially called Gas Tungsten Arc Welding (GTAW). The tungsten electrode used in the process is a non-consumable electrode.
Like MIG welding, this is a welding technique that requires the use of shielding gas in order to keep the weld pool from deteriorating due to porosity issues. Argon is the inert gas that is often used with TIG Welding.
The fact that the tungsten electrode is non-consumable allows the welder to bond metal pieces together without having to use a filler metal, even though filler metals are often used anyway. TIG welding can be used in metal-to-metal welds and results in a cleaner weld zone.
One caveat to TIG welding is that it requires more refined welding skills than MIG and flux core welding. You must take care to not overheat the weld as it can result in stress cracks and other similar deficiencies in the finished weld.
TIG welding is also not very effective at welding thicker metal pieces. If you are welding a piece that is approximately 3/16” thick or thicker, then flux core welding will be your best bet. Tig welding was invented to weld thin metals for applications like aerospace. It is fantastic for some metals and particular thicknesses, but not all. It also works best when you are able to back purge when your TIG welding job.
All in all, flux core welding is a unique, simple to learn, versatile welding technique that can work where other techniques cannot. If you work outside primarily, and in the positions mentioned above, this would be worth checking out for welding jobs around the house or farm. Thanks for reading and keep stacking dimes!
