MIG Welding User Guide: Difference between revisions

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'''Procedure Number'''
'''Procedure Number'''


UG 130-03, Rev. 1
UG 130-03, Rev. 2
|width="33%"|
|width="33%"|
'''Date'''
'''Date'''


2/4/2021
8/17/2022
|}
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= GENERAL =
= GENERAL =


The Millermatic 211 is both a stick welder and a MIG welder, see sister Stick Welding Guide UG 130-02 and Maintenance Guide MT 130-02
The MIG welder is used for fusing steel and aluminum. We have Lincoln 350MP MIG welders.
 


[[File:Millermatic 211 Stick and MIG Welder.png]]
[[File:Millermatic 211 Stick and MIG Welder.png]]
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= SAFETY =
= SAFETY =


* Always wear approved face shield while operating the welder.
* Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes when welding or watching.  
* Wear a welder helmet that fits your head, face and neck comfortably. It should cover the top of your head down to where your head and neck meet. Those with a mask that lifts are helpful because they let you take a peek at your work, but you may want an auto-darkening helmet too that comes with shields designed for different jobs.
* Wear approved welding gloves and jacket.
* Wear approved welder’s gloves and jacket.
* Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.
* Wear dry, hole-free insulating gloves and body protection.
* Before operating equipment, remove tie, rings, watches and other jewelry, and roll sleeves up past the elbows. Remove all loose clothing and confine long hair.  
* Before operating equipment, remove tie, rings, watches and other jewelry, and roll sleeves up past the elbows. Remove all loose clothing and confine long hair.  
* Non-slip footwear or anti-skid floor strips are recommended.
* Closed toe shoes are required when working in a shop area.
* Closed toe shoes are required when working in a shop area.
* Turn off all equipment when not in use.  
* Turn off all equipment when not in use.  
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* Do not drape cables over your body.
* Do not drape cables over your body.
* Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.  
* Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.  
* Insulate work clamp when not connected to workpiece to prevent contact with any metal object.
* Do not connect more than one electrode or work cable to any single weld output terminal.
* Do not connect more than one electrode or work cable to any single weld output terminal.
* Do not touch hot parts bare handed.
* Do not touch hot parts bare handed.
* Allow cooling period before working on gun or torch.  
* Allow cooling period before working on gun or torch.  
* To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
* Keep your head out of the fumes. Do not breathe the fumes.  Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.
* Keep your head out of the fumes. Do not breathe the fumes.  Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.
* Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.
* Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.
* Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.
* Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.  
* Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes when welding or watching.
* Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc.
* Wear approved safety glasses with side shields under your helmet.  
* Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc.
* Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.


= REFERENCE =
= REFERENCE =


* The Millermatic 211 is both a stick welder and a MIG welder, see Stick Welding Guide UG 130-02 [File:https://vector-space.org/wiki/Stick_Welding_User_Guide] and Maintenance Guide MT 130-02 [File:https://vector-space.org/wiki/Stick_welding_maintenance_and_specifications]
* Millermatic 211 Manual (https://www.millerwelds.com/files/owners-manuals/o239988d_mil.pdf)
* https://www.millerwelds.com/files/owners-manuals/o239988d_mil.pdf
* MIG welding basics video (https://www.youtube.com/watch?v=v62lm7FGhNc)
* YouTube video - Stickl Welding https://www.youtube.com/watch?v=3_K9-kB6HRk
* Lincoln 350MP User Manual (https://www.lincolnelectric.com/assets/servicenavigator-public/lincoln3/im859.pdf)
* https://www.millerwelds.com/resources/article-library/five-steps-to-improving-your-stick-welding-technique
* MIG welding settings chart (https://weldguru.com/wp-content/uploads/wire-selection-settings-chart-large.jpg)
* [https://www.youtube.com/watch?v=v62lm7FGhNc MIG welding basics]


= PROCEDURE =
= PROCEDURE =


'''For general instruction, see Stick Welding Guide UG 130-02'''[File:https://vector-space.org/wiki/Stick_Welding_User_Guide]
# Power on welder.
 
# Open MIG gas bottle and ensure correct flow rate at the regulator.
[[File:MIG Change Polarity.png]]
# Set wire speed to Automatic for 0.030" wire, as this is the wire diameter that should be loaded.
 
# Set voltage dial according to the material thickness being welded.
[[File:4-13 Removing MIG Gun From Welding Power Source.png]]
# Connect ground clamp to workpiece or work surface.
 
# Ensure proper PPE is in use and safe surroundings.
[[File:4-14 Connecting Spool Gun To Millermatic 211.png]]
# Weld
 
# When finished, store welding cables properly
[[File:4-14-1 Connecting Spool Gun To Millermatic 211.png]]
# Turn off welder
 
# Close gas bottle
[[File:5-1 MIG Controls.png]]
 
[[File:5-1-1 MIG Controls.png]]
 
[[File:MIG Process Connections.png]]
 
[[File:8-2 Typical MIG Process Control Settings.png]]
 
[[File:8-2-1 Typical MIG Process Control Settings.png]]
 
[[File:8-16 MIG Shielding Gases.png]]
 
<u>'''Shielding Gas Bottle'''</u> – make sure it is always chained up, either to the machine or somewhere in the shop. If it falls over with a regulator on it, the gas will try to escape and the gas stream could potentially hurt someone. To prevent the escape of gas when not in use, remove the regulator and fasten a threaded protector cap to the top of the bottle to keep the valve system safe and help prevent a rupture.
 
 


= TROUBLESHOOTING =
= TROUBLESHOOTING =

Latest revision as of 09:09, 27 July 2023

Shop Area: Metal Shop

Tool: MIG Welding

Requires in-person training: Yes 

Procedure Number

UG 130-03, Rev. 2

Date

8/17/2022


GENERAL

The MIG welder is used for fusing steel and aluminum. We have Lincoln 350MP MIG welders.


Millermatic 211 Stick and MIG Welder.png

SAFETY

  • Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes when welding or watching.
  • Wear approved welding gloves and jacket.
  • Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.
  • Before operating equipment, remove tie, rings, watches and other jewelry, and roll sleeves up past the elbows. Remove all loose clothing and confine long hair.
  • Closed toe shoes are required when working in a shop area.
  • Turn off all equipment when not in use.
  • Do not use worn, damaged, undersized, or poorly spliced cables.
  • Do not drape cables over your body.
  • Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.
  • Do not connect more than one electrode or work cable to any single weld output terminal.
  • Do not touch hot parts bare handed.
  • Allow cooling period before working on gun or torch.
  • Keep your head out of the fumes. Do not breathe the fumes. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.
  • Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.
  • Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.
  • Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc.

REFERENCE

PROCEDURE

  1. Power on welder.
  2. Open MIG gas bottle and ensure correct flow rate at the regulator.
  3. Set wire speed to Automatic for 0.030" wire, as this is the wire diameter that should be loaded.
  4. Set voltage dial according to the material thickness being welded.
  5. Connect ground clamp to workpiece or work surface.
  6. Ensure proper PPE is in use and safe surroundings.
  7. Weld
  8. When finished, store welding cables properly
  9. Turn off welder
  10. Close gas bottle

TROUBLESHOOTING

8-8 MIG Troubleshooting − Excessive Spatter.png

8-9 MIG Troubleshooting − Porosity.png

8-10 MIG Troubleshooting − Excessive Penetration.png

8-11 MIG Troubleshooting − Lack Of Penetration.png

8-12 MIG Troubleshooting − Incomplete Fusion.png

8-13 - 14 MIG Troubleshooting − Burn-Through and Waviness.png

8-15 MIG Troubleshooting − Distortion.png 


                                                      END OF THE PROCEDURE
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