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Mig Welding Equipment at Engweld
There are many different products that a professional welder or hobbyist would need if they want to engage in Mig Welding. Luckily, Engweld is a true expert in welding and the MIG process, offering an enormous range of high-quality mig welding products that will make the process as easy and precise as possible. What's more, all the MIG welding products you see here at Engweld are sourced from only the very best and most trusted branding in MIG welding, including Lincoln Electric, Parweld, ESAB and many more. This means you can rest assured that any of the following products purchased here today can be relied upon for a long time to come.
Most Popular MIG Welding Categories:
MIG Welding Information
What is MIG welding?
MIG (Metal Inert Gas) is an arc welding process in which a continuous solid filler metal (consumable) electrode is fed through a welding torch and into the weld pool, joining the two base materials together. The weld pool is protected from contamination by a shielding gas passed through the torch. MIG welding is also known as GMAW (Gas Metal Arc Welding).
MIG welding is essentially a semi-automatic process, with the rate at which the wire is fed and the length of the arc controlled at the source of the power. However, the wire position and the speed at which the weld travels are manually controlled. As the welder moves the welding torch along the line of the joint, the wire is fed out by a motor-driven reel, the type of welding wire varies depending on the type of metal you wish to weld.
What is MIG Welding used for?
MIG welding is typically used for large and thick welding materials. As the consumable wire has dual functions, acting as the electrode and as the filler material, there is no need to hold a separate welding rod, enabling single handed and much faster welding. This welding method is relatively simple to learn, and requires little post weld cleanup and finishing. MIG welding consumables are relatively inexpensive, which, combined with the speed and efficiency of MIG welding, allows for short lead times and low costs.
Things To Consider In MIG Welding
MIG welding machine: The right MIG welder will depend on your application and requirements. Engweld stocks a wide range of MIG welders including compact and industrial MIG welders, as well as multi-process MIG welders designed to handle multiple welding processes, including MIG, TIG, and MMA welding. The choice includes air-cooled and water-cooled MIG welders.
There are many MIG welders out there to choose from and we have put together a guide to choosing the right MIG welder.
MIG Welding torch: A MIG welding torch feeds the filler metal consumable electrode wire and directs the flow of the shielding gas to protect the weld pool from contamination. A welding torch usually comes with a welding machine and Engweld also stocks a wide range of MIG torches including air-cooled and water-cooled torches.
Consumable electrode wire: A MIG welding wire (consumable) is used as the filler material that becomes the weld bead. A welding torch continuously feeds through the MIG welding wire into the welding area. Engweld stocks various types of MIG welding wires for different applications including mild steel, stainless steel, aluminium, copper, flux-cored wires, and hard-facing and specialist MIG wires.
Shielding gas: MIG welding involves a shielding gas to protect the weld pool from contamination. Gas selection depends upon each welding application and different mixtures are optimized for each transfer mode and material being welded. Read our list of our recommended welding gases depending on your welding process and the material/thickness you're welding.
Engweld’s parent company Energas supplies various welding gases. You can use the gas selector tool or download the gas selector guide to help you choose the right gas for your welding application.
Read our guide on gases used for MIG welding and TIG welding.
Gas regulator: A gas regulator will control the flow rate of the shielding gas from the gas cylinder. Engweld stocks different types of MIG gas regulators including single-stage, multi-stage, Nevoc (300bar), and high-pressure gas regulators.
Welding PPE: Before undertaking any welding project, you need to make sure you have the appropriate personal protective equipment (PPE) for welding. Any arc welding will generate an extremely bright light which can damage your eyes so you will need a welding helmet/welding mask. There are two types of welding helmets; manual and auto-darkening welding helmets. In the manual one, you have to change the lenses and shades appropriate for the welding task. An auto-darkening welding helmet will sense the light from the welding and automatically change the shade within nano-seconds.
Depending on the application, you may need an air-fed welding helmet with a PAPR (Powered Air Purifying Respirator) system to protect yourself from hazardous welding fumes. See our guide for welding fume extraction.
MIG welding involves extremely high temperatures and spatters so you will need MIG welding gloves, a welding jacket, and welding trousers to protect yourself from any hazards.
Check out our guide for MIG welding gloves.
Earth clamp: you will need an earth clamp to secure the connection between the energiser and earthing system for optimum electrical conductivity. Engweld stocks earth clamps ranging from 200A to 600A.
Travel angle: Travel angle is defined as the angle relative to the torch in a perpendicular position. Normal welding conditions in all positions call for a travel angle of 5 to 15 degrees. Travel angles beyond 20 to 25 degrees can lead to more spatter, less penetration, and general arc instability.
The rate at which you move the welding torch along the joint can have a significant impact on the quality of a weld bead.
Weld finish: if you used too much welding wire resulting in a messy weld then you can fix it by grinding the weld with a grinding disc on an angle grinder. Grinding is used to hide the weld or to get a neater and smoother-looking finish.
If you don’t already have an angle grinder and need to buy one then don’t forget to go through our guide for buying angle grinders.
If you are a beginner and want to learn more about MIG welding then check out these tips for MIG welding.
Modes of MIG (GMAW) Transfer
Modes of transfer refer to the processes by which the wire electrode is melted and deposited into the puddle. There are 3 different modes of MIG transfer; Short Circuit Transfer, Globular Transfer, and Spray Transfer.
Globular: A globular transfer for GMAW is often referred to as the state of transfer between short-circuiting and spray arc transfer. Large “globs” of weld metal transfer across the arc in a gravity transfer. The droplets are usually larger than the electrode wire. Although the electrode wire is pinched off at the arc, globular transfer does not achieve a true spray transfer.
Globular is the least popular of the 3 modes of transfers because it creates a more unstable transfer, with a less smooth weld bead appearance. Another downside of globular transfer is that it creates waste due to high spatter in many cases. Globular transfer can also cause cold lapping or incomplete fusion due to the large metal droplets splashing metal out of the puddle.
Short Circuit Transfer: gets its name from the welding wire actually “short-circuiting” (touching) the base metal many times per second. When the trigger on the welding torch is pressed, the electrode wire feeds continuously from the wire feeder, through the torch, and to the arc area, short-circuiting to the base metal, exploding, and establishing an arc. While welding, this cycle can repeat itself between 20 and as much as 250 times per second.
In short-circuiting transfer the current is lower than the globular transfer. The lower current allows lower heat input for the short-arc variation which makes it possible to weld thinner materials and reduce the stress and distortion on the residual area.
Spray Transfer: A spray transfer “sprays” a stream of tiny molten droplets across the arc, from the electrode wire to the base metal. Those molten droplets are usually smaller than the diameter of the unmelted electrode wire. The arc is said to be “on” all of the time, once an arc is established.
The spray transfer uses relatively high voltage (24 volts or higher depending upon the type of shielding gas), wire feed speed, and amperage values, compared to short circuit transfer. Because of the high voltage, wire feed speed, and amperage, there is a resulting high current density. The current density produces high metal deposition rates. The high degree of heat in the spray arc weld puddle makes for a larger weld puddle that is more fluid than the weld puddle for short-circuit transfer. Because of this heat and the size of the weld puddle, spray transfer is somewhat limited in welding positions. The heat and size of the weld puddle also limit spray transfer to material ⅛” or thicker.
Advantages and Disadvantages of MIG welding
Advantages of MIG welding
- Higher productivity: one of the main reasons MIG welding is preferred over other welding processes is that it offers speed. You can weld more in less time, making it suitable for applications requiring long welds. MIG welding offers high deposition rates and fast travel speeds thanks to the wire feed system.
- Less Stop and Starts: MIG welding allows continuous welding, unlike other welding processes such as stick welding where you have to stop and start every now and then.
- Easier to learn: MIG welding is relatively simpler and easier to learn compared to other welding processes such as TIG and MMA welding. The MIG welding torch is also easier to operate.
- Versatile: MIG welding offers versatility as you can weld various metals and alloys, including stainless steel, copper, aluminium, nickel and iron.
- You can read more about welding aluminium and stainless steel.
- Better visibility: MIG welding offers excellent visibility of the weld pool so you can produce consistent and quality welds.
- No stub end losses: In welding processes like stick welding, you end up wasting some part of the welding stick which is called the stub loss. In the MIG welding process, there are no stub end losses because you can use all the continuously fed welding wire.
Disadvantages of MIG welding
- Limited positions: MIG welding process involves high heat input and a very fluid weld puddle making it unsuitable for certain applications such as overhead welding positions.
- Maintenance: MIG welding machine and the torch will require regular maintenance to get optimum performance.
- Burn-through: MIG welding is generally not suitable for welding very thin materials that are less than 0.5mm as it can result in burn-throughs. However, it depends on your welding skills and you may be able to work around it with the right techniques.
Read our helpful MIG Welding FAQs guide for more info. If you would like to know more about MIG welding or have any questions or queries, then please contact us and speak to one of our experts.