MIG Welding Training Notes

Dress appropriately.
Most of the welding will involve sparks generated which can ignite materials.
Long hair must be tied back. Avoid hair gels; they can be flammable.
Wear cotton clothes without loose threads or frayed edges which might catch
fire from flying sparks. If possible wear fire resistant clothing. Avoid clothing with
pockets as they can catch and hold sparks that can burn. Do not wear synthetic
materials; they can catch fire but will also melt and stick to your skin.
Metal watches, rings and jewelry should be removed when welding. They
conduct electricity and could cause you to get a shock. They also can become quite
hot and even melt
The high levels of uv light emitted from the electric welding processes can
produce a sunburn on exposed skin. Welding helmets and goggles with the
appropriate shade of filters are provided for eye and face protection. Gloves and
welding jackets will be provided for those doing the welding. Participants will be
issued welding beanies to protect hair.
Do not wear open-toed footwear.

Reference Books

The Haynes Welding Manual Storer and Haynes

The Procedure Handbook of Arc Welding- Lincoln Electric Company

Welders Handbook A Complete Guide to MIG, TIG, Arc & Oxyacetylene

Welding HP Books Finch
Modern Welding Althouse, TurnQuist and Bowditch
www.osh.govt.nz/order/catalogue/pdf/hotwork.pdf ( procedures for hot work on tanks
and drums.

Manual for Miller Model Millermatic 251 MIG welder

www.millerwelds.com

On the site the manual can be downloaded as a pdf

As well as welding safety information.

Welding Standards

Canadian Welding Bureau (CWB)

American Welding Society (AWS)

FIRE SAFETY

Welding and some of the operations associated with it such as cutting (oxyacetylene, plasma) and grinding are in a classification of work designated as hot
work.
Hot work is defined as any work or operation that will create an ignition source for
fire.
A primary concern for welding is fire. Fires produce intense heat and often cause the
release of toxic chemicals and gasses.

Classes of Fires
There are several classes of fires, these being defined by the material that is
burning.

Class A
Class A fires are solid materials that can burn when heated up to their combustion
temperature. These are combustible materials such as wood, cardboard, many

plastics and paper. Extinguishing this type of fire involves separating the flame form
the material and cooling it. Water is very effective on this type of fire.

Class B
Class B fires are burning liquids such as fuels ( gas, kerosene, diesel) or solvents
(acetone, paint thinners, alcohol, etc.). These liquids often produce vapours at room
temperatures. These vapours can easily be ignited to produce a fire. Water cannot
be used on these types of fire. Extinguishing the fire involves the use of CO2 or
chemical type fire extinguishers.

Class C
Class C fires are electrical fires. The electricity produces both the heat and the
source of ignition. These fires are often the result of bad electrical connections
(producing both heat and an electric arc), overloaded circuits or conductors or
electrical short circuits. The first step to extinguishing these fires is to disconnect
the power source. This eliminates the source of heat, electric arcing and the risk of
electrical shock. Chemical type fire extinguishers are used, using a non conducting
chemical. CO2 Fire extinguishers can be used as well as they do not leave a residue.
Sometimes, the welder itself can be the cause of an electrical fire if the cables get
burnt and start shorting out.

Class D
Class D fires are reactive metals or chemicals burning. Metals, such as magnesium,
uranium ( DU or isotopes), strontium, titanium, potassium, sodium, phosphorus will
react violently with water, as well as the oxygen in air. The conventional ABC fire
extinguisher will not work on these types of fires. The method of extinguishing these
types of fires is to use graphite powder, or sodium chloride to smother the fires and
let the metal cool. The powders must be moisture -free.

Fire extinguishers

Website information

www.fire-extinguisher101.com
www.fireextinguisherratings.org
www.osha.gov/doc/outreachtraining/htmlfiles/extmark.html
safety.eas.ualberta.ca/node/15

Fire extinguishers are rated by the classes of fires that they can be used on and
their capacity. A class ABC fire extinguisher must be available when welding.
More importantly is to prepare the welding site to eliminate the possibility of fire in
the first place.

SAFETY- GENERAL

The welding will be done in an area that has exhaust fans to extract the
welding fumes.
NOTE:
Welding must be done in well ventilated areas. The areas must be dry and
cleared of flammable and combustible materials. Fire extinguishers must be readily
available.
Screens are used to shield others from the uv light.

There are several safety issues that arise when welding.

Hot metal
High levels of uv light
Many of the processes produce flying sparks
Wearing the appropriate clothing
Using the appropriate face and eye protection
Using gas cylinders
Ventilation to remove welding fumes (and welding shielding gases)

Avoiding electric shock.

The Weight and Size of Workpieces
Welding and hot work on contaminated, coated material and containers

Hot Metal
Do not attempt to pick up any metal or material unless you are certain that it
is not hot. Burns can result. Hot metal can also start fires.

High Levels of uv Light

All of the electric arc welding processes produce high levels of uv light. Your eyes
and face must be shielded with a welding helmet with the appropriate lens shade
(No. 10 filter minimum) Failure to comply can result in a painful injury known as
welders flash which is essentially a sunburn on the retina of your eyes. This light is
bright enough to pass through closed eyelids. When in relatively close proximity or
prolonged exposure, your skin can also be sunburned. All skin areas need to be
protected; leather welding gloves for hands, leather welding jacket with a high collar
for the upper body, cotton pants, closed footwear, preferably safety ankle boots,
leather apron as required.

Flying Sparks
Flying sparks can start fires if combustible materials are present. They can also
cause burns on exposed skin. Dress appropriately and position yourself to minimize
your exposure to them.

Wearing Appropriate Clothing

This is provide protection from uv light exposure and burns from flying sparks. This
is important as it is used in conjunction with the protective wear worn when
welding. Same recommendations as per uv light protection.
Clothing Guidelines

Wear cotton clothing; do not wear synthetic clothing as synthetic materials if they
catch fire will melt and stick to skin and burn instead of just burning.
Wear a welding beanie to protect hair. Do not use hair gels or hair spray as these
can be flammable.
Wear leather welding gloves to protect hands
Wear a leather welding jacket to protect clothes from catching fire and to provide
skin protection.
Wear closed type footwear, preferably leather and preferably ankle boots tucked
under the pants to prevent sparks from entering the footwear or igniting socks.

Wearing the Appropriate Eye and Face Protection

MIG Welding requires a welding helmet with at least a No. 10 filter to protect from
the uv light. No. 12 is recommended for the current used for welding 3/16 steel.
Safety glasses are be worn under the helmet as the work is being done in a
workshop.
Gas Cylinders
Gas cylinders are used upright and chained to the welder on its cylinder rack when
in use. For storage, when not on a machine or welding cart, they must be stored
upright and chained to a wall.
With MIG welding of steel, there are three gases used CO2, Argon and Argon-CO2
mixes. Aluminum uses pure argon or for very heavy sections may use an argon
helium mix.
Acetylene cylinders have a maximum pressure of 250 psi due to the nature of that
gas. It is explosive on its own above 15psi so it is supplied dissolved in acetone in a
cylinder filled with pith to stabilize it. Acetylene regulators are red lined above
15psi. to indicate the hazards of higher pressures. All fuel gas cylinders, hoses,
fittings and components have left hand threaded fittings to avoid them being
interchanged with those used with other types of gases.
Inert gases and Oxygen cylinders have maximum pressures of 2000psi. The fittings
and hoses have right hand threads.
Components used for Oxygen service must be degreased and cleaned appropriately
prior to use with oxygen. The heat of compression created when an oxygen cylinder
is opened is enough to ignite a contaminated line or fitting.

Gas cylinders, when not in use must be turned off (Ontario OH&S Act & Regulations
- Reg .122.(3)).
Do not hang welding cables or ground over gas cylinders (Ontario OH&S Act &
Regulations - Reg .124.(1)).

Ventilation
Metals often contain harmful elements in them or on them (used during fabrication
or coatings ) Welding areas must be ventilated to remove them and minimize
exposure. Shielding gases are used to keep oxygen from reacting with the molten
metal and can also gradually displace the oxygen (for breathing ) in a confined room
if not ventilated out. Dust masks or respirators are recommended when required.

Avoiding Electric Shock

When welding, stay dry. Welding currents are often quite high and shocks can result
if the operator is wet (and more conductive). Electrode holders, torches and guns
are insulated and should only be held on the insulated parts.

The Weight and Size of Workpieces

When welding larger workpieces, care must be taken when handling them. Be aware
of the weights of the pieces involved. Have proper material handling equipment to
lift and support large pieces. Ensure that clamps and fixtures have the capacity for
the weights and sizes of materials involved. Use proper lifting techniques to avoid
back injury and know the limits for weight when manually lifting smaller pieces.
Appropriate CSA approved safety footwear must be worn to avoid foot injury should
a piece be dropped or falls.

Welding and Hot Work on Contaminated, Coated Material and Containers

Hot Work is defined as work that can be a source of ignition, such as work involving;
an open flame, an electric arc, extreme heat such as soldering, heat from grinding,
or a spark from grinding or using steel tools. These sources can ignite flammable
vapours, or can generate heat that produces flammable vapours, or gasses. Toxic
gasses or chemicals can also be generated from the heat. It is not recommended
that novice welders attempt this type of work. Even experienced welders should

become familiar with the procedures and protocols for dealing with this type of
work. Often elaborate cleaning and testing procedures must be followed to ensure
that the work can be done safely.
Closed containers also have a risk of explosion when heated due to the vapours
present, or generated through the hot work involved (welding, cutting, grinding
etc.).

MIG Welding (GMAW)

MIG (Metal Inert Gas) welding is a semi-automatic type of arc welding. The MIG
welding process consists of a DC constant potential power supply, a welding gun, a
wire drive mechanism, a controller and a shielding gas supply. The consumable wire
is fed through the gun with a gas shielding. Typical wire sizes are 0.024, 0.030,
0.035 and 0.045. For welding steel, MIG equipment can use solid wire (GMAW), a
flux cored electrode wire that requires gas shielding or self-shielding flux cored wire
(FCAW). Other metals, such as stainless steel, and aluminum use solid wire (with
gas shielding). The shielding gases used for other metals vary with the material.
For welding steel, CO2, argon or combinations of these are commonly used.
CO2 gives a deeper penetration but leaves more spatter and a brown powder
residue surrounding the weld. It is also a relatively cheap gas to use but cleanup
labour costs can offset this lower gas cost. Argon is cleaner and leaves less spatter
but has much lower penetration. Compromise mixtures are often used such as a C25 Mix ( 25% CO2 and 75% argon ) that require minimal cleanup but still have
adequate penetration. There are proprietary mixtures sold under various trade
names but these are basically refinements of CO2 and Argon mixes with small
percentages of additional gases in the mix. For steel, most gas shielded MIG welding
is much cleaner than stick welding and is faster than both TIG and stick welding.
Most other metals (non-ferrous), use argon or argon helium mixes. Helium is used
for higher heat requirements but helium is much more expensive to use than argon.
The welding gun cable consists of a liner that feeds the electrode wire, a
power cable, the trigger control wires, and a gas hose. The power is applied to the
electrode wire with a contact tip located within the gas shielding nozzle. The actual
current passing through the electrode wire to the work depends on the distance
between the contact tip and the work. This is known as the wire stickout. A larger
stickout causes higher resistance resulting in a lower current. Changes in stickout
cause major changes in the welding current. Typical ranges for stickout is from 3/8
(10mm) to (12mm).

The welding gun and cable do not have to be connected to the welder
directly. Industrial MIG welding may use a separate wire feeder unit that is supplied
power from the power supply but is located closer to the work. Another method of
MIG is called Spool-in-Gun where a small wire spool is located in the back of the gun
unit and the power and gas are fed to this unit. Spool-in-Gun units are sometimes
used when welding aluminum. With a Spool-in-gun unit, the wire feed control is on
the gun, but the voltage is still set at the machine.
Wire feed and control units are of two basic types; push type and push-pull
types. With push type feeders there are drive rolls located in the welder or the wire
feed unit that push the wire through the length of the liner to the contact tip. This
can be a problem with pushing thinner wires or softer wires such as aluminum
through a long gun cable. This can result in a tangle of wire in the gap between the
liner and the drive rolls, referred to as a birds nest. With push-pull types of guns,
there is one set of drive rolls located in the welder or wire feeder and another set
located in the gun. With these, gun cable lengths of up to 30 feet can be used.
MIG welding power supplies are DC machines, but, they are unlike stick and
TIG units. MIG power supplies are constant potential type power supplies. The
operator sets the output voltage but the current will vary depending on the
electrode wire stickout. To be productive, MIG welders must have a high duty cycle.
Inexpensive units often have low duty cycles sometimes as low as 15 or 20%. The
duty cycle, input voltage(s) required , and maximum output voltage and current is
listed on the welder, either on the front panel or near the on- off switch.
When the trigger on a MIG Gun is pressed, three events occur; a gas solenoid
opens to start the shielding gas flow through the gun nozzle, the contactor closes to
apply power to the electrode wire, and, the drive rolls start feeding the wire. When
the trigger is released, the contactor opens, the drive rolls stop feeding the wire and
there is a short post flow of shielding gas to protect the molten metal from the air
until it freezes. On a spool-in-gun unit, there is often a 2 position trigger to allow the
operator to start a pre-flow of shielding gas before closing the contactor and
starting the wire feed. This is due to the fact that these units are often used for
aluminum welding where a pre-flow of shielding gas is important.
The setup of a MIG welder for welding consists of setting the voltage, the
feed rate of the wire and the gas flow rate. A chart for the starting settings is
usually located on the inside of the cover for the wire spool on the welder. It will list
the material, the thickness of material, the MIG wire diameter, the shielding gas
and flow rates and the process (GMAW, FCAW).It will also list the polarity ( DCEP,
DCEN) to be set. From the chart, the wire feed rate, gas flow rate, and voltage
setting will be given.

MIG welding requires lower operator skill than other processes such as oxyacetylene, stick electrode or TIG. The sequencing of the welding, to minimize
distortion still requires experience.

MIG Welding Equipment

MIG Gun

Inside View of MIG Welder

Welding Techniques Used
With MIG welding, both a push technique and a pull (or drag) technique of torch
movement can be used. An exception to this is aluminum where only a push
technique can be used. This is because the push technique causes the oxides to
break off the surface ahead of the welding.
Using a pull / drag technique provides better weld penetration but it is more difficult
to see where you are going than with the push technique.