How do you calculate wire feed speed on a MIG welder?
Multiply the required amperage of your weld by the burn rate associated with the diameter of the wire to calculate the feed speed. Using our example, you would multiply the 125 amps by the 2 inch burn rate to calculate a feed speed of 250 inches per minute.
What is the flow rate for MIG welding?
What is the gas-flow rate on a MIG welder? As a guide, around 12-14 lpm (litres per min), this can be set on the gauge on gas regualtor, for finer control we recommend using a gas flow meter, this can save gas from over use (too higher flow rate).
What happens when you weld too fast?
Move too quickly, and the arc may not have enough time to adequately melt the base material, leading to a thin, narrow weld with poor fusion and penetration.
What is the proper gas setting for MIG welding?
Gas for MIG welding mild steel A 75 percent argon/25 percent carbon dioxide blend (also called 75/25 or C25) works as the best all purpose shielding gas for carbon steel. It produces the least amount of spatter, best bead appearance and won’t promote burn-through on thinner metals.
Why are my MIG welds so bad?
Wire feed speed/amperage too high – Setting the wire feed speed or amperage too high (depending on what type of machine you’re using) can cause poor arc starts and lead to an excessively wide weld bead, burn-through and distortion.
What are the 7 common mistakes in MIG welding?
start MIG welding:
- They don’t prep their material.
- Volts too high or too low.
- Wire feed speed too high or too low.
- Electrical stick-out that is too long or short.
- Gas Flow too low or high.
- Travel speed too fast or slow.
- Gun angle to steep.
Why does my MIG welder splatter so much?
A common cause of MIG welding spatter is excessive speed or irregularity with your wire feed. Spatter occurs when the filler wire enters the weld pool. The solid wire melts at a rapid rate due to the extreme heat. As it melts, the filler wire turns into a liquid form, creating the pool.
Why is my MIG welder popping?
The wire is hitting the surface and not melting into the metal fully. You will feel the wire pushing back on the MIG gun because of this, and you will hear a lot of random popping from the welder.
What should gas pressure be set at for MIG welder?
A good starting point is 20 to 25 CFH. Keep an eye on the weld surface and the area around weld toes. If you notice porosity, increase the flow. Using a tri-mix shielding gas (i.e., 10% Ar + 85-90% He + 2-5% CO2) increases the amount of helium when you increase the gas flow rate.
How far should MIG tip stick out?
Keep your wire stickout to 1/4 to 3/8″ (stickout means the distance the wire is extending from the end of the contact tip.) This one simple tip can have the biggest effect on your mig welding. I have gone over this before on other pages but it warrants repeating again and again.
How to calculate MIG welding wire feed speed?
To calculate MIG welding wire feed speed, you need to multiply the necessary current of your welding by the flame rate connected to the wire’s diameter so that you can calculate the speed of the feed. Using this method, you can simply multiply the current of 100 amps by the 3-inch flame rate to determine a wire feed speed of 300 in. per min.
How do you find the feed speed of a wire?
For example, for .030-inch wire, multiply by 2 inches per amp to find the wire feed speed in inches per minute (ipm). One way to check your parameters is by examining the weld bead. Its appearance indicates what needs to be adjusted.
What is the MIG wire used for in welding?
This wire acts both as the electrode that arcs with the metal being welded to create the weld bead and as filler material to join the metal pieces. To ensure a proper joint is created, the MIG wire must be fed to the weld at an appropriate speed.
What size MIG wire do I need for 125 amp welding?
Identify the diameter of the MIG wire that you will be using for your weld. The wire manufacturer lists a wire burn rate in inches per ampere on the packaging. For example, the 0.030 gauge wire required of 125 amp welding has a burn rate of 2 inches of wire per 125 amps.