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By pressing the trigger that completes the welding circuit, the operator activates the mechanism that feeds the electrode to the arc. The operator uses a gun instead of an electrode holder, but it is similarly light in weight and easy to maneuver. The only other major difference is that the weld metal of the electrode surrounds the shielding and fluxing chemicals rather than being surrounded by them. Full-automatic welding with self-shielded flux-cored electrodes goes one step further in mechanization the removal of direct manual manipulation in the utilization of the open-arc process. One of the advantages of the self-shielded flux-cored arc-welding process is the high deposition rates that are made possible with the hand-held semiautomatic gun. Higher deposition rates, plus automatic electrode feed and elimination of lost time for changing electrodes, have resulted in substantial production economies wherever the semiautomatic process has been used to replace stick-electrode welding. Decreases in welding costs as great as 50 percent have been common, and in some production welding, deposition rates have been increased as much as 400 percent. Another advantage of the process is its tolerance of poor fitup, which in shops often reduces rework and repair without affecting final product quality. The tolerance of the semiautomatic process for poor fitup has expanded the use of tubular steel members in structures by making possible sound connections where perfect fitup would be too difficult or costly to achieve.
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26.6.3 Gas Metal-Arc Welding Gas metal-arc welding, popularly known as MIG welding, uses a continuous electrode for filler metal and an externally supplied gas or gas mixture for shielding. The shielding gas helium, argon, carbon dioxide, or mixtures thereof protects the molten metal from reacting with constituents of the atmosphere. Although the gas shield is effective in shielding the molten metal from the air, deoxidizers are usually added as alloys in the electrode. Sometimes light coatings are applied to the electrode for arc stabilizing or other purposes. Lubricating films may also be applied to increase the electrode feeding efficiency in semiautomatic welding equipment. Reactive gases may be included in the gas mixture for arc-conditioning functions. Figure 26.5 illustrates the method by which shielding gas and continuous electrode are supplied to the welding arc. MIG welding may be used with all the major commercial metals, including carbon, alloy, and stainless steels and aluminum, magnesium, copper, iron, titanium, and zirconium. It is a preferred process for the welding of aluminum, magnesium, copper, and many of the alloys of these reactive metals. Most of the irons and steels can be satisfactorily joined by MIG welding, including the carbon-free irons, the lowcarbon and low-alloy steels, the high-strength quenched and tempered steels, the chromium irons and steels, the high-nickel steels, and some of the so-called superalloy steels. With these various materials, the welding techniques and procedures may vary widely. Thus carbon dioxide or argon-oxygen mixtures are suitable for arc shielding when welding the low-carbon and low-alloy steels, whereas pure inert gas may be essential when welding highly alloyed steels. Copper and many of its alloys and the stainless steels are successfully welded by this process. Welding is either semiautomatic, using a hand-held gun to which electrode is fed automatically, or done with fully automatic equipment. The welding guns or heads are similar to those used with gas-shielded flux-cored welding.
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Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright 2004 The McGraw-Hill Companies. All rights reserved. Any use is subject to the Terms of Use as given at the website.
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FIGURE 26.5 Principle of the gas metal-arc process. Continuous solid-wire electrode is fed to the gas-shielded arc. (The Lincoln Electric Company.)
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26.6.4 The Gas-Shielded Flux-Cored Process The gas-shielded flux-cored process may be looked on as a hybrid between selfshielded flux-cored arc welding and gas metal-arc welding. Tubular electrode wire is used (Fig. 26.6), as in the self-shielded process, but the ingredients in its core are for fluxing, deoxidizing, scavenging, and sometimes alloying additions rather than for these functions plus the generation of protective vapors. In this respect, the process has similarities to the self-shielded flux-cored electrode process, and the tubular electrodes used are classified by the American Welding Society (AWS) along with electrodes used in the self-shielded process. However, the process is similar to gas metal-arc welding in that a gas is separately applied to act as arc shield. The gas-shielded flux-cored process is used for welding mild and low-alloy steels. It gives high deposition rates, high deposition efficiencies, and high operating factors. Radiographic-quality welds are easily produced, and the weld metal with mild and low-alloy steels has good ductility and toughness. The process is adaptable to a wide variety of joints and has the capability for all-position welding.
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26.6.5 Gas Tungsten-Arc Welding The AWS definition of gas tungsten-arc (TIG) welding is an arc-welding process wherein coalescence is produced by heating with an arc between a tungsten electrode and the work. A filler metal may or may not be used. Shielding is obtained with a gas or a gas mixture.
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Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright 2004 The McGraw-Hill Companies. All rights reserved. Any use is subject to the Terms of Use as given at the website.
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