Normal stickout is usually around 3/8 inch. Increasing this stickout puts less heat into the metal and can decrease the coverage of the gas shield. I normally push the puddle when I weld.
For wire (flux-core or MIG) welding, keep a work distance of ⅜ to ½ inch. With stick welding, look to keep that distance ⅛ inch between the rod tip and work piece. "The arc length should not exceed the diameter of the core of the electrode," Leisner says.
A general rule of thumb is you need 1 amp of power for every 0.001 inches of steel. Stainless needs 10-15 percent less current, and aluminum needs around 25 percent more. So, how many amps does it take to weld 3/8 steel? For 1/8-inch mild steel, which is 0.125-inch thick, 125 amps would be a good place to start.
Stick-out distance may vary from 1/8 to 1/4 in. (3.175 mm to 6.35 mm). Short electrode extensions (1/8–1/2 in. (3.175–12.7 mm)) are used for the short-circuit mode of transfer generally with the smaller diameter electrodes (0.023–0.045 in.
A good rule of thumb is to keep the welding wire stickout at 5/8 inch or shorter for small diameter wires. It helps control amperage and with it, heat input and more. Too long of a stickout lowers the amperage, which reduces penetration but fights against the voltage setting used.
Holding the Gun
Although you can do MIG welding one handed if you want, it is best to use both hands to keep a constant space between the work and the tip.
Several issues in the MIG welding process can contribute to excessive spatter, including: Insufficient shielding gas. Dirty base materials, contaminated or rusty weld wire. Voltage or travel speeds that are too high.
The upside down V is one of the most effective techniques for vertical mig welding of lap and tee fillet welds. Sure there are other ways of making a good looking vertical uphill weld, but for ensuring penetration as well as making a good looking uniform weld, the upside down V is a very good way to go.
Poor penetration in MIG welding can also be caused by joint design. It can help to open up the bevel angles of the joint or use a wider root opening. Overlapping, also called cold lap, happens when the filler metal doesn't fuse into the base material at the weld toes.
MIG welding is generally the easiest type of welding for a beginner to learn. MIG welders use a feed wire that runs through the machine at a preselected speed. This makes the process relatively fast and produces consistent welds.
No, it's not advisable to touch the rod while welding due to potential UV/IR radiation and heat. Make sure you have all the right safety gear and follow protocols before starting.
MIG welding setup
Use a metal brush or grinder and clean down to bare metal before striking an arc. Make sure your work clamp connects to clean metal, too. Any electrical impedance will affect wire feeding performance.
Is MIG welding hard to learn? MIG welding is generally the easiest type of welding for a beginner to learn. MIG welders use a feed wire that runs through the machine at a preselected speed. This makes the process relatively fast and produces consistent welds.
For novice welders, MIG welding is incredibly versatile, quick, and easy, but it does have a high setup cost, isn't appropriate for windy conditions, and is prone to burn-throughs.
When you weld metals to repair with the MIG, the excessive heat of the welding machine can cause the metal to burn through. Burn through may occur because of Parameters – travel speed, heat input, and travel angle.
The author notes that four of the most difficult metals to weld are aluminum, cast iron, brass, and stainless steel.
Take Precautions Against Electrocution
Electric shock is one of the most important topics for welders to be educated in, as it can pose an immediate and serious risk. To avoid electrocution, welders must always inspect the electrode holder for damage before starting their weld.
Both acute and chronic health risks are associated with welding fume. Occupational lung disease, including lung cancer, is the most common health risk, but welding can also affect the eyes and skin.
4. Physical Strength and Endurance. Welding can be a physically taxing job, which is why being strong and able to endure some difficult workplace conditions is a great skill to have. Depending on your job, you may need to lift a considerable weight and pick up objects that could weigh to 50 to 100 lbs or even more.