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MIG Welding Gauge Steels and Alloy Steel Part1

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    MIG Welding gauge steels and alloy steel parts < 1/8 (< 4 mm).

    The bove actually happened because the plant management and engineersresponsible for the bomb lug welds did not understand or take ownership ofthe MIG weld process and equipment used in their plant.

    HAVE YOU SEEN THE WORLD'S BEST WELD PROCESS TIP TIG? www.tiptigusa.com.

    http://www.weldreality.com/Tip%20Tig%20brochure%20em.pdfhttp://www.weldreality.com/weld_process_quiz.htmhttp://www.weldreality.com/Tip%20Tig%20brochure%20em.pdfhttp://www.weldreality.com/weld_process_quiz.htmhttp://www.weldreality.com/Tip%20Tig%20brochure%20em.pdfhttp://www.weldreality.com/weld_process_quiz.htmhttp://www.weldreality.com/Tip%20Tig%20brochure%20em.pdfhttp://www.weldreality.com/weld_process_quiz.htm
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    THIS UNIQUE WELD PROCESS PROVIDES LESS WELD HEAT AND BETTER WELDQUALITY THAN ANY TIG OR MIG WELD AND PROVIDES THO WELDS AT A THIRD OFNORMAL TIG WELD COSTS.

    Welcome to MIG Short Circuit welding and Pulsed MIG onCARBON STEELS AND STAINLESS GAGE APPLICATIONS.

    As the pulsed MIG process painfully evolved over the last few decades, the utilization ofshort circuit decreased for gauge, carbon steel applications. The weld reality is that incontrast to pulsed MIG, the lower cost traditional CV MIG equipment that provides shortcircuit welding can offer many unique superior weld attributes for most thin gaugesteels and alloy steels none code weld applications.

    Note: This site has been a weld blog long before the word blog was discovered. Thissite cuts out the salesmanship from an industry that depends on sales advice anindustry that has too many weld decision makers that have to play around with 50 yearold simple weld controls.

    This site brings the weld process contol expertise I gained over 40 years and this sitebrings the opinions of other weld personnel that also strive to see this industry gain therespect it deserves.

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    During short circuit weldtransfer, unlike the open arcpulsed, globular or spraytransfer modes, the uniqueshort circuit arc spends 50% ofit's time in the "arc off"

    condition.

    When the electrode positiveshort circuit weld wire makescontact with the negativegrounded part it's in the arc offcondition. This cold conditionis controlled by the powersource slope. With the shortcircuit, the resistance to thecurrent is lowered, the weldvoltage drops and the current

    rises to the slopes limit. The short circuit current rise is sufficient to melt the wire tip

    and form an arc which results in the formation of a fluid droplet that quickly develops onthe MIG wire tip.

    As the short circuit wire feed is constant, the weld dropletbeing formed is driven to the weld and also drawn bycapillary action into the surface of the weld. The shortcircuit weld droplet is detached and the wire is driven tothe weld to repeat the arc off, arc on cycle which typicallyoccurs 60 to 120 times per-second.

    Note: With argon gas mixes, the argon mix gas plasma (asindicated in the video below) partially covers the fluid

    droplet during it's formation. In contrast, when usingstraight CO2, the CO2 plasma would be at the bottom of the weld droplet, supporting thedrop and disturbing the drop till it gets larger and then transfers in an erratic manner.

    A UNIQUE ATTRIBUTE OF SHORT CIRCUIT TRANSFER WELDING: The short circuitmode is the only weld metal transfer in which the arc goes on - off. The "arc on - off"weld attribute is a logical weld benefit on thin gauge, or applications which require agap has to be bridged.

    If welding stainless and steel thin gauge applications, short circuit is an excellent weldtransfer mode, however stainless produces more sluggish welds than carbon steelwelds. The sluggish welds welds are especially noted on stainless parts > 0.080. If youwant gage welds with minimum distortion, minimum spatter and minimum cleaning,watch what TIP TIG www.tiptigusa.com can do for thin stainless in the following video.

    REGULAR TIG VERSUSTIP TIG ON THIN GAGE APPLICATIONS:

    http://www.weldreality.com/TIP-TIG-Welding.htmhttp://www.weldreality.com/TIP-TIG-Welding.htmhttp://www.weldreality.com/TIP-TIG-Welding.htm
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    REGULAR TIG: YOU CAN USE REGULARTIG, TAKE TOO MUCH TIME, PUT IN TOOMUCH WELD HEAT AND MAKE WELDSLIKE THIS. PLAY THIS VIDEO FIRST

    TIP TIG: YOU COULD GET ON WITH YOUR LIFE,REDUCE YOUR WELD COSTS. MAKE HIGHQUALITY TIP TIG WELDS LIKE THIS WITH MUCHLESS HEAT INPUT.

    REGULAR TIG: Play this video first:Regular TIG typical manual weld speeds forthese welds is 4 to 7 inch/min.

    The TIG arc on time for this 12 inch weldwould be around 2- 3 minutes. Take a look

    at the irregular weld quality influenced bytoo many arc start / stops, and take specialnote of the large heat affected zone that'sgoing to create distortion concerns.

    Someone can always do a better TIG weldthan this but it will never match the qualityand productivity attained with TIP TIG.

    TIP TIG: Manual TIP TIG weld travel rate48 inch/ min as noted on the UTube secondcounter with this 12 inch length of 3 mm weldmade with an arc on time of 15 seconds:

    Note the uniform weld quality that comes from theconstant wire feed rate and only one arc start /stop. Examine the smooth clean, unoxidized weldsurface, the very small HAZ and lack of welddistortion and weld minimal fumes. Think aboutthe savings that will results from less cleaning.

    From welding small, long track, 3 mm fillet weldson the deck of an Aircraft Carrier to the small sizestainless welds typically found on food andbeverage / processing equipment, no other weldprocess can provide long, small size gage weldswith the TIP TIG quality and the lowest possibleweld heat input.

    On robot stainless gauge applications > 0.070, thanks to the increased weld speedpotential, low spray parameters and an 0.035 wire can be used. Pulsed MIG with 0.045wire is also applicable but not necessary when manual welding > 16 gauge stainless

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    parts.

    A Short Circuit and Pulsed Transfer WeldConsideration.Short circuit welding transfer available from a lowcost, constant voltage, (CV) traditional MIG power

    source with an 0.035 (1mm) wire is suited for allmanual steel applications from 20 to 12 gauge.

    Note: A benefit of the pulsed mode for some > 16 gauge applications is the lower cost,easier to feed, 0.045 (1.2 mm) carbon steel or stainless wire may be used instead of the0.035 (1 mm) wire. 045 wire provides a little more deposition which may be beneficialwhen larger welds are required on specific thin parts. As a lower cost weld equipmentalternative you could take regular, much lower cost CV MIG equipment and set that0.045 in the globular mode and achive the same deposition as the pulsed MIG..

    Designers and manufacturing engineers and managers of gage applications often sufferfrom a lack of MIG weld process knowledge and that can lead to dramatic weld costconsequences.

    When welding thin, carbon steel or stainless robot welded parts < 2mm you may find;

    [a] unacceptable part part tolerances,[b] unacceptable weld gaps,

    [c] poor part fixtures,[d] inappropriate weld joint designs,[e] poor consumable wire size selection and weld equipment with poor performance,[f] poor weld parameters and poor technique.

    Of course items A to F will lead to weld rework and weld cost ramification. Commonissues are weld burn through, distortion, spatter leading tp weld rejects and extensiveor rework. To add to the thin gauge weld issues, it's a sad fact that the majority manyautomotive and truck manufacturing plants that use MIG welding robots, lack the

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    engineering ability to select the correct size MIG wire or the optimum weld transfermode for the application.

    ED OPTIMIZED ROBOT WELDS FOR HUNDREDS OF COMPANIES. A FEW OF HIS PROJECTS,FORD F 150 FRAMES - VOLVO TRUCK CABS - CORVETTE FRAMES- HARLEY BIKE FRAMES -NEW BEETLE CAR SEATS AND THE ROBOT WELDS ON THE WORLD'S LARGESTCATERPILLARTRUCK.

    Ed's unique manual and robotMIG Process Control Training Programs

    STEEL GUAGE CHART, OPTIMU WIRE SIZE & WELDING GAS MIXTURE.

    http://www.weldreality.com/eds_training_materials.htmhttp://www.weldreality.com/eds_training_materials.htmhttp://www.weldreality.com/eds_training_materials.htmhttp://www.weldreality.com/TIP-TIG-welding-videos2.htmhttp://www.weldreality.com/TIP-TIG-welding-videos2.htmhttp://www.weldreality.com/eds_training_materials.htm
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    Gauge to inch conversion

    GAUGE 3 = 0.239 inch O.6 cmGAUGE 4 = 0.224 inch 0.56 cm

    CONSIDER 0.045 (1.2 mm) WIRE. ARGON-10-15 C02 FOR THESE MANUAL / ROBOT SPRAY

    / PULSED WELDS.

    GAUGE 5 = 0.209 inch 0.53 cmGAUGE 6 = 0.194 inch 0.49 cm

    CONSIDER 0.035 (1 mm) WIRE.ARGON-10-15% C02 FOR MANUAL / ROBOTSPRAY. IF USING PULSED USEDAN 0.045 WIRE WITH THE SAME GAS MIXES.

    GAUGE 7 = 0.179 inch 0.45 cmGAUGE 8 = 0.164 inch 0.41 cm

    CONSIDER 0.035 (1 mm) WIRE. ARGON 5-10%

    C02 OR ARGON 2 TO 5% OXYGEN FOR THISMANUAL / ROBOT SPRAY WELD . IF USINGPULSED USED AN 0.045 WIRE WITH THESAME GAS MIXES

    GAUGE 9 = 0.15 inch 0.37 cmGAUGE 10 = 0.135 inch 0.34 cm

    CONSIDER 0.035 1 mm WIRE.

    ARGON 5-10% C02 OR 2 TO 5% OXYGEN FORTHIS MANUAL / ROBOT SPRAY WELD. IFUSING PULSED USED AN 0.045 WIRE WITHTHE SAME GAS MIXES,

    GAUGE 11 = 0.12 inch 0.3 cmGAUGE 12 = 0.105 inc

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