A Guide to MIG Welding: Tips, Techniques, and Applications

Posted on Apr 15, 2024

MIG welding, or Gas Metal Arc Welding (GMAW), is one of the welding processes that has been widely used across industries because of its efficiency.  In this guide, we’ll explore the basics of MIG welding, including tips, techniques, and applications to help you get started or improve your existing skills.

What is MIG Welding?

MIG welding uses a continuous power feed as an electrode that passes through a welding gun, creating an arc between the wire and the workpiece. Shielding gas is also used to protect the weld pool from contaminants, resulting in a clean and strong weld. The process is relatively simple and suitable for a wide range of materials such as steel, aluminum, and stainless steel. 

Tips for Effective MIG Welding

1. Choose the Right Equipment: Consider the duty cycle, input power, and the types of materials you will be welding. Opt for a machine with adjustable settings for greater control.

2. Select the Proper Shielding Gas: The choice of shielding gas depends on the material you’re welding. For steel, a common mix is 75% argon and 25% carbon dioxide. For aluminum, pure argon is often used.

3. Use the Correct Wire: Choose a welding wire that is compatible with the material you’re working on. For steel, ER70S-6 is a common choice since it has a deoxidizer for steel that has been corroded. For aluminum, consider using ER4043 or ER5356.

4. Set the Right Parameters: Adjust the wire feed speed and voltage according to the material and thickness. Refer to the machine’s manual for recommended settings.

5. Practice Good Welding Techniques: Maintain a consistent travel speed and a steady hand. Keep the torch at the correct angle (around 15 to 20 degrees) for optimal penetration and weld quality.

6. Prepare the Material: Clean the workpiece thoroughly to remove any rust, paint, or other contaminants. This ensures a strong, clean weld.

7. Use Proper Safety Gear: Protect yourself with appropriate safety gear, including welding gloves, helmet, and clothing. Avoid loose-fitting garments to prevent catching fire.

Techniques for Quality Welds

1. Push vs. Pull: Pushing the torch away from the weld creates a flatter bead, while pulling it towards you results in deeper penetration. Experiment with both methods to see which suits your needs.

2. Stringer Bead: Use a steady hand to create a straight-line weld. This technique is ideal for thin materials.

3. Weave Pattern: For thicker materials, use a zigzag or oscillating motion to create a wider bead and ensure full penetration.

4. Tack Welding: Secure the pieces together with tack welds before performing a continuous weld. This helps maintain alignment and reduces distortion.

Applications of MIG Welding

MIG welding is used in various industries and applications:

• Automotive: Ideal for welding auto body panels and repairing frames.
• Construction: Used for structural steelwork and other metal fabrication projects.
• Manufacturing: Employed in the production of machinery, appliances, and other metal products.

About PEN Manufacturing

Pen Manufacturing has been servicing California's precision metal parts, structural steel, and sheet metal needs for over 40 years. Our full-service machine shop focuses on leveraging the highest technology equipment with our experienced skilled team members. As a firm specializing in MIG welding in the state of California, Pen Manufacturing maintains industry certifications from the American Welding Society in welding of the following:

• AWS D1.1 - Structural Steel
• AWS D1.2 - Aluminum
• AWS D1.6 - Stainless Steel