6 MIG Welding Mistakes to Avoid
MIG welding offers loads of benefits, including high quality welds without sacrificing productivity. However, some common missteps can interfere with MIG welding success, costing you both time and money. Here are six often-made mistakes to avoid them.
Mistake #1: Improper liner length.
When you cut the liner to the wrong length, it can cause all kinds of problems, from wire chatter and an erratic arc to poor wire feeding. It’s why accurate trimming is key and locking the liner into place at both ends of the gun.
Mistake #2: Overheated consumables.
Another issue occurs when consumables are overheated, which can lead to burn back and vibrations in your gun. Avoid it with the proper contact-to-tip work distance, as well as keeping the gun’s duty cycle in mind.
Mistake #3: Poor ground.
If you don’t have a solid ground, it can shorten the life of the consumables and contact tip. In addition, the arc can be erratic, which leads to more heat build-up and more wear, damaging the front-end consumables and contact tip. Prevent this by securely connecting the ground cable as close to the workpiece as possible.
Mistake #4: Improper wire feed speed.
With MIG welding, most power sources are constant-voltage (CV) type. This means you set voltage and wire feed speed, and amperage is the result of the wire feed speed and electrical stick-out (ESO). High wire feed speeds produce high welding currents and just the opposite for low wire feed speeds. Too high, and you will get a ropey looking weld or burn through the base material. Too low, and you may end up with lack of fusion (LOF) at the root or undercut the base material.
Mistake #5: Poor cable management.
This can lead to welding performance problems and even damage to the cables. Don't drag the welding machine or wire feeder around by the welding gun or electrical cables. Make sure to regularly inspect these components for wear and tear, or any other damage.
Mistake #6: Drive roll issues.
Improper drive roll tension is yet another common mistake, which leads to erratic arcs, and poor wire feeding, or even damage the wire. To set the proper tension, start by releasing the tension on the drive rolls. Then, increase the tension while feeding the wire into your gloved hand at approximately 3 inches away. At first, the wire will not feed so keep increasing the tension until it begins to feed and curl up as it deflects off your glove. At this point, back off the tension approximately a 1/4 turn, this will be the recommended drive roll tension. Also, avoid excessive loops or bends in the welding gun which will create unnecessary drag on the wire.