The quality of the basket's welds directly impacts its ability to satisfy the buyer. Welding, however, entails more than simply applying heat to the wires of the basket and fusing them together. For any particular metal shape, there exists a wide variety of specialised welding methods.
A wire basket's ability to withstand tension can be improved by employing proper welding techniques. But there are a lot of issues that might arise from employing the incorrect welding procedure, such as weaker bonding, corrosion of the weld joint, or not finishing the weld at all.
Inert metal gas (MIG) and tungsten inert gas (TIG) welding are two of the most popular welding methods utilised in American manufacturing facilities. Although there are some similarities between the two arc welding processes, one may be preferable in certain circumstances. When should one employ MIG welding as opposed to TIG welding?
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Table of Contents
What’s the Difference Between MIG and TIG Welding?
There's nothing wrong with feeling a little confused. After all, both metal inert gas (MIG) and tungsten inert gas (TIG) welding involve the utilisation of electrical arcs to generate heat and combine metals. An inert gas combination is used in both methods to protect welding electrodes from oxidation.
Electrical arcs are used in both MIG and TIG welding processes. The arc's implementation is the key differentiator between the two. In MIG (inert metal gas) welding, the spark is produced by a feed wire that travels continuously through the gun, melts, and forms the weld. Long rods are used in TIG (inert tungsten gas) welding, which fuses two metals directly.
However, there are significant distinctions between these two electrical arc welding procedures that influence when you would choose to utilise one or the other:
How Does a MIG Welder Work?
In MIG welding, also known as inert metal gas welding, a metal wire is constantly fed into the weld site. The welding wire, a consumable supply, is used as a filler material to help fuse the metal pieces together. The acronym GMAW describes this method (Gas Metal Arc Welding).
Marlin Steel's engineers begin by loading the workpiece onto a MIG welding robot and programming the robot to do the weld. It is common practise to employ a woodblock cut using a wood routeing machine to brace the joint to prevent the workpiece from sliding during the weld and so destroying the angle of the junction. The robotic welder then swiftly and precisely rotates the welding arm so that the resulting heat is dispersed uniformly across the weld.
There must be a distinction between the gas mixtures utilised for MIG and TIG welding. You shouldn't use pure helium or some other inert gas for shielding purposes. This is due to the fact that the arc properties of the filler-metal-arc-gas (MIG) method differ greatly from those of the tungsten-inert-gas (TIG) welding operation, and hence the use of the incorrect gas would have a detrimental effect on the quality of the arc weld.
As an added precaution, after each welding session, the MIG welder must be thoroughly cleaned. Weld spatter is an unwanted byproduct of employing filler material for a weld and can occur at any welding speed. As a result of spatter, the weld joint may develop sharp edges, or "spatter burrs," which should be removed through a secondary operation like as sanding or electropolishing to prevent harm.
These days, MIG welding is far more common than TIG. Getting started with MIG welding is quicker and easier than with other welding methods.
How Does a TIG Welder Work?
Tungsten arc welding (also known as TIG or tungsten inert gas welding) (Gas Tungsten Arc Welding). A TIG welder consists of a consumable tungsten electrode, a computerised controller for timing welding operations, and a robotic arm assembly for positioning the welding tip. TIG welding, in contrast to MIG welding, is not required to employ filler metal in the welding supply.
TIG welder machines, like MIG welding robots, are pre-programmed to carry out the actual welding process. Sparks or filler metal released during TIG welding could cause serious injury to workers. Robots are programmed to carry out the welding while a human welder monitors the process to ensure safety and quality.
To prevent contamination of the welding region, an inert gas is employed during the procedure. Argon and helium are two examples of common inert gases used in TIG welding. TIG welding, in contrast to MIG welding, typically does not require the use of a filler, albeit one is employed when joining metals with high melting temperatures to prevent cracking.
TIG welding for direct metal-to-metal welding eliminates the need for post-weld finishing operations like electropolishing by eliminating weld spatter on the workpiece surface, which can be caused by filler materials.
In tungsten inert gas welding, a tungsten electrode is used to conduct electricity between the two metal pieces. The electrode melts the metal, and then the welder dips the filler material by hand to unite the two parts.
With TIG welding, you need to utilise both hands, as the torch and filler material are held in different devices. TIG welding, however, can be performed without using any filler metal at all. To regulate the current going to the torch, TIG welders typically have a foot pedal. Spatter is an unavoidable byproduct of several types of arc welding. TIG welding produces less spatter and better finishes.
When Should you use MIG vs. TIG Welding?
When should you choose one of these two welding methods over the other?
You might be able to push your project to the next level by using MIG or TIG welding. Creating it would take much less time and work, but the finished result would be of far higher quality and last much longer.
By learning what kinds of jobs MIG and TIG welds excel at, you can determine which one to utilise for your personal project.
To help you decide between MIG and TIG welding, keep the following in mind:
How Thick Are the Two Pieces of Metal Being Joined?
TIG welding becomes less effective when working with thicker pieces of sheet metal because more energy is required to heat them to the melting point. Some metals may be better welded with MIG technology due to their thickness.
MIG welding is the way to go if your project calls for thicker, larger chunks of metal and a lot of welding. Your desired end product will be assembled using a filler material fed constantly from a spool to join the individual parts. There may be some finishing work, such as grinding or smoothing, that has to be done after this type of welding is performed.
What Is the Electrical Conductivity of the Metal Being Joined?
It's also important to think about how ductile the metal being connected is. Heat is generated to fuse metal in an electric arc welding process due to the electrical resistance of the metal when the electric arc tries to pass through the weld site. Higher energy costs are associated with heating highly ductile metals. Metals having a high resistance to electrical current can be welded with less filler material thanks to their increased welding temperature.
Am I Welding Dissimilar Metals?
Weak bonding, weld corrosion, and other problems might arise when welding incompatible metals, thus it's best to avoid doing so unless absolutely necessary. It's best to utilise a welding method that involves the use of a filler substance to build a bond between different metals. It is important to select the correct filler material, though.
Is Surface Condition/Smoothness Important?
Weld spatter is more likely to be left on a workpiece when filler materials are used, necessitating additional finishing steps if surface imperfections must be eradicated. Bypassing the need for filler material, direct metal-to-metal welding results in welds that are often more cleaner.
Metal arc welding processes have clear advantages and disadvantages, making it simple to determine which one is ideal for a given job. The Marlin engineering team uses virtual physics simulation software to double-check their assumptions and ensure the welded joint will behave as predicted, even when the option seems clear.
What’s the Difference Between MIG and TIG?
Both metal-inert-gas welding (MIG) and tungsten-arc welding (TIG) have their uses and advantages. Examining your project's end goals and the steps leading up to them will help you determine the path that will get you there most efficiently. Think about how much welding experience you have, the materials you'll be using, how much time you have, and how much money you have available.
Some of the Differences Between MIG and TIG Welding Include:
DIVERSITY
Because of its many advantages, MIG welding is the best method for your needs. First of all, there's a wider range of people represented. TIG welding's versatility means it can be used on a wider variety of metals than MIG welding, but it struggles to hold its own when working with thicker materials. MIG welding may be performed on a wide variety of metals, from aluminium to steel, and on sheet metal as thin as 26 gauge to as thick as heavy-duty structural plates.
When MIG welding, the wire feed serves as both the electrode and the filler, giving it a significant advantage over TIG. Therefore, it is not necessary to completely melt the thicker portions in order to fuse them together. Because technique does not involve fusing the materials together, MIG welding can be used to join dissimilar materials.
SPEED
Compared to TIG, MIG welding is much quicker. A MIG gun has the advantage over its competition since it can operate nonstop for extended periods of time. MIG is the prefered method when high output rates are essential, as they are in industrial settings. (It's also amenable to robotization.) TIG welding, on the other hand, is a much slower procedure that emphasises precision.
For high-volume production jobs, MIG welding is the superior option. TIG is a more leisurely process, but the results are more precise.
COST
When working in production, time is money. In addition to being more economical, the MIG welding process is significantly faster. MIG parts are also far more accessible and affordable compared to TIG.
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TIG is a more expensive method than MIG welding.
EASE
Last but not least, MIG welding is more intuitive and can be mastered with a minimum of time invested in training. You may start and stop the weld by simply pulling the trigger, earning it the nickname "hot glue gun" of welding. The MIG welding gun is easier to use for beginners because it only requires one hand. In contrast, TIG welding is a specialised technology that calls for the use of both hands and a single foot to perform distinct tasks.
As a rule, MIG welding is the prefered method due to its simplicity. The method is generally recommended for first-time operators and non-professionals since it is somewhat more tolerant of mistakes than TIG welding is.
However, TIG welding calls for meticulous management of the weld's time, pressure, and power. TIG welding is often performed best on a CNC welding equipment, which is fully automated and controlled by a computer. Repeated, identical welds can be performed by a machine with significantly greater ease and consistency than by a human welder.
Making the same error over and over while using an automated welder (whether MIG or TIG) is a real possibility if the weld parameters and controls aren't optimised.
Object Thickness
MIG welding is quicker and better for thicker metals than TIG welding. TIG welding may be more practical if the metal being worked with is relatively thin.
For the most part, MIG welding may be used on any metal. Materials like aluminium and mild steel are also acceptable. TIG welding can also be performed on these metals, albeit it is more effective on thinner sheets.
The thickness of the object. MIG welding is faster than TIG welding, even on thicker metals. TIG may be preferable if the metal being worked with is somewhat thin.
MIG welding can be done on a wide variety of metals. Aluminum, stainless steel, and mild steel are all viable options. TIG welding can also be done with these metals, albeit it is more effective on thinner sheets.
Technique
The approach taken is the key differentiator between the two. With MIG welding, the weld is made by constantly feeding an electrode wire through a spool gun. When TIG welding, the welder must use one hand to control the torch and the other to apply filler material to the weld.
Difficulty
MIG is less complicated to use than TIG since the wire is constantly being fed to the torch. For beginners, TIG welding can be challenging due to the need to juggle the welding flame and filler material with one hand.
Project Size
Which type of welding you use may depend on the scope of your project. MIG welds are useful for large-scale projects that involve thick metals and require lengthy, uninterrupted runs. TIG welds are prefered when working with thinner metals or on smaller projects due to their precision and cleanliness.
Control
Welding using MIG is more intuitive and suitable for novices. Experience in timing and balancing materials in both hands is essential for TIG welders.
Appearance
The smooth, attractive appearance of TIG welds is a major draw for many customers. Because of its aesthetically pleasing results, this style of welding is frequently employed in the creative and decorative industries.
What Are the Similarities Between MIG and TIG Welding?
Since an electric arc is formed between the electrode and the base plates during both TIG and MIG welding, the faying surfaces are melted and the plates are welded together. Since the joining of these base metals involves fusing them together, they are also considered fusion welding methods.
The naked electrode is used in both methods. In neither of these procedures is a flux-coated electrode used, even though the electrode material is distinct.
Shielding gas must be supplied from outside sources in both scenarios. Whereas shielding gas is obtained naturally during the MMAW or FCAW process as a result of the decomposition of the flux available with the electrode, this is not the case here.
In both circumstances, inert shielding gas is employed to prevent the oxidation and contamination of the hot weld bead. For protection, only inert gases like argon, helium, nitrogen, or a combination of these are used.
Only conductive metals can be joined using these two methods. Actually, you can only use arc welding techniques on metals that are also conductive. You can use solid-state welding on metals that don't conduct electricity.
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What Are the Components of MIG Weld?
Power
The power comes from a DC source that maintains a steady voltage.
Wire
Welding uniformity depends on a reliable wire-feed system. Pinch rolls, push-pull, and spool-on-gun are all types of feeding mechanisms.
Electrode
Choosing the correct diameter and composition for your MIG weld is crucial, and it depends on the project at hand.
Torch
The welding current is transferred from the wire to the arc via the gas provided by the welding torch. Both air and water can be used to cool torches. For the most part, air-cooled torches are more affordable and more portable than their water-cooled counterparts. The nozzle is cooled by the gas that is passing through it. It's best used for less intensive welding jobs. When welding with a high current and undertaking heavy work, water-cooled guns are the way to go.
Conduit
For smooth feeding, make sure the pipe is both short and straight.
Filler Metal
It not only helps the electrode melt, but it also helps to hold the weld together.
Gas Shielding
Protective gas for the weld pool and arc typically consists of argon and carbon dioxide.
What Are the Components of TIG Weld?
Power
DC or AC power can be used. On some welding machines, you'll find a toggle for selecting your favourite currency. Aluminum, which conducts electricity well via AC, is ideal. A powerful arc can be achieved with a DC power source; however, the workpiece needs to be cleaned first.
Torch
There's a lot of room for creativity when it comes to the shape of a TIG torch. The on/off switch and other controls may be included in the handle, or they may be operated via a foot pedal.
Foot Pedal
This switches on and off the power supply for the torch. As your foot presses down on the pedal, more power flows through, heating up the arc. The welding process can be sped up in this way, but it's important to know how to deal with the increased heat and velocity.
Electrode and Gas Shielding
The arc that creates the weld pool is shaped by the angle of the electrode tip. Maintaining its quality between welds is essential. A gas lens for gas flow via the torch nozzle is required for arc and weld pool protection. The amount of gas released depends on the size of the nozzle used. Typically, argon is utilised as the gas.
Filler Material
It's possible to find filler rods in a wide range of materials and dimensions. The size of the filler rod is determined by the thickness of the material being welded.
Backing Bars
These assist in bringing down the temperature of the weld zone more rapidly than would be possible with just air. Clamping backing bars to the back of the welded item. Copper or aluminium can be used for a backing bar because of their different thermal conductivities. There is also an option for a backing bar to be cooled by water, which circulates cold water through the bar to bring down its temperature more quickly.
What Are the Pros and Cons of Mig and Tig Welding?
Considering the benefits and drawbacks of MIG and TIG welding in light of your specific project is essential.
You may have a preference for a specific welding method, but it's important to weigh the pros and cons before settling on the one that will help you achieve your objectives and produce the finest welding results for your project.
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MIG PROS
The welding process can be completed faster with MIG.
Cost-Effective - Compared to TIG welds, this method saves money and the necessary equipment is easier to come by.
MIG welding bonds more precisely and easily than other methods.
Welds made with this method are cleaner and require less maintenance afterwards.
MIG CONS
Inadequate Strength - Unlike TIG welding, MIG often produces welds with inferior strength.
Reduced arc stability and wire burn-back are two variables that reduce the reliability of this weld process.
MIG welding is more dangerous since it can produce large amounts of smoke and fumes, as well as sparks.
Deposition of rust is possible using this technique.
Minimum Material Thickness - MIG welds can melt through thin metals.
Ambient Restrictions - The gases used make this technique impractical for usage in the open air.
MIG welding is effective on a wide variety of metals, but different wires and gases are needed for each material.
TIG PROS
Accuracy - Compared to MIG welds, TIG welds offer a greater degree of accuracy and overall superior quality.
The TIG method is more eco-friendly and produces fewer emissions.
TIG welding doesn't call for any filler material, therefore there's no need to stock up.
Enhanced Regulability: The pedal's range of motion enables for fine-tuning of heat output with the press of a foot.
TIG welds require less upkeep than MIG welds since the welding electrode is not used up throughout the welding process. Even though cleaning the electrodes between uses is the only real maintenance they require, they nevertheless require attention.
TIG CONS
As a slower process with lower deposition rates, TIG welding is more expensive than MIG welding. Welding deposition rate is expressed as a function of welding current in pounds per hour.
Required Clean Surface - Prior to beginning this procedure, the welding surface must be cleaned properly.
TIG welding is more complex to accomplish, hence it demands a more skilled operator.
Time Required to Complete Task is Greater: Both Preparation and Welding Take More Time Using This Approach.
Conclusion
Common welding processes in American factories include metal inert gas (MIG) and tungsten inert gas (TIG). Welding and soldering both use electrical arcs to create heat and join metals together; in both processes, an inert gas mixture is used to shield the electrodes from oxidation. While both of these electrical arc welding methods are commonly used, there are notable differences between them that dictate when to use each. When MIG welding, a metal wire is fed into the weld site while when TIG welding, long rods are used to fuse two metals directly. The engineers at Marlin Steel use a MIG welding robot to complete the weld, which requires a woodblock cut and the use of a wood routeing machine to brace the joint.
To ensure that the resulting heat is distributed evenly across the weld, the robotic welder rotates the welding arm. Since MIG welding and TIG welding use different gas mixtures, employing the wrong gas for either process can negatively affect the quality of the arc weld. Welding spatter can cause sharp edges, or "spatter burrs," so it's important to clean the MIG welder after every use. Although TIG welding is still used, MIG welding has gained popularity because it is simpler and faster to perform. Like their MIG-welding robotic counterparts, TIG welders can be set to automatically perform the welding process once power is applied.
Both metal-inert gas (MIG) and tungsten-arc (TIG) welding are used to keep the welding area clean. TIG welding, which employs a tungsten electrode to conduct electricity between the two metal pieces, requires additional post-weld finishing operations like electropolishing, whereas MIG welding does not. Because more energy is needed to bring thicker pieces of sheet metal to the melting point, TIG welding is less efficient for use with thicker pieces of sheet metal, but it is better for thicker, larger chunks of metal and a lot of welding. Both tungsten arc welding (TIG) and metal-inert gas welding (MIG) have their uses and benefits, but they also have their drawbacks. In comparison to TIG welding, which can be used on a wider variety of metals but struggles when working with thicker materials, MIG welding is the best method for your needs because of its versatility and ability to work with a wider range of metals.
In order to verify that the welded joint will perform as expected, the Marlin engineering team uses virtual physics simulation software. Use a welding technique that incorporates a filler substance to create a strong weld when joining metals that aren't naturally compatible with one another. Welds should be as clean as possible, and direct metal-to-metal welding usually achieves this. When it comes to mass production, MIG welding is the go-to technique because of its low cost, high efficiency, and general accessibility. It's less complicated than TIG welding and can be used by novices with no prior experience.
TIG welding, on the other hand, is best carried out on CNC welding equipment due to the precision with which the weld's time, pressure, and power must be managed. MIG welding is faster and more effective for thicker metals, while TIG welding may be more practical for thinner metals. TIG welding is more effective on thinner sheets of metal, but both MIG and TIG can be used with a wide range of metals including aluminium, stainless steel, and mild steel. MIG welding is created by continuously feeding an electrode wire through a spool gun, which is the primary methodological distinction between the two. The welding flame and filler material for TIG welding must be managed with one hand, making it difficult for novices.
TIG welds are frequently used in the decorative and creative industries due to their smooth, aesthetically pleasing appearance, which is a major selling point for many customers. Both MMAW and FCAW employ the bare electrode but require additional sources of shielding gas. Inert shielding gas is used in both processes to protect the hot weld bead from oxidation and contamination. These two techniques are limited to joining conductive metals together, with the welding current being transferred from the wire to the arc by means of the gas produced by the welding torch. Wire-feed systems include pinch rolls, push-pull, and spool-on-gun, and are powered by a DC source that maintains a steady voltage.
Depending on the nature of the welding job at hand, the correct diameter and composition for the MIG weld must be selected. Conduit Maintaining a short, straight pipe is essential for uninterrupted feeding. The filler metal not only aids in the melting of the electrode, but also acts as a binding agent for the welded joint. The weld pool and arc can be safeguarded with gas shielding.
The advantages and disadvantages of MIG and TIG welding are discussed at length in this article. Although MIG welding is less expensive and quicker than TIG welding, the welds it creates are weaker and more easily damaged due to decreased arc stability and wire burn-back. When compared to stick welding, TIG welding produces fewer byproducts and requires less upkeep, but it can be more challenging to maintain due to its higher temperature and speed. It's important to think about the benefits and drawbacks of each welding technique before settling on one for your project. While TIG welding produces minimal smoke and fumes, MIG welding can deposit rust and melt through relatively thin metals, making it a more hazardous option.
Although MIG welding is useful for a wide range of metals, specialised wires and gases are required for use with each. TIG welding is more precise and high-quality than MIG welding, while also being less harmful to the environment, emitting fewer harmful gases, and requiring less maintenance. However, the price tag and operator expertise requirements are higher.
Content Summary
- The quality of the basket's welds directly impacts its ability to satisfy the buyer.
- A wire basket's ability to withstand tension can be improved by employing proper welding techniques.
- Inert metal gas (MIG) and tungsten inert gas (TIG) welding are two of the most popular welding methods utilised in American manufacturing facilities.
- Although there are some similarities between the two arc welding processes, one may be preferable in certain circumstances.
- There's nothing wrong with feeling a little confused.
- After all, both metal inert gas (MIG) and tungsten inert gas (TIG) welding involve the utilisation of electrical arcs to generate heat and combine metals.
- Electrical arcs are used in both MIG and TIG welding processes.
- In MIG welding, also known as inert metal gas welding, a metal wire is constantly fed into the weld site.
- Marlin Steel's engineers begin by loading the workpiece onto a MIG welding robot and programming the robot to do the weld.
- This is due to the fact that the arc properties of the filler-metal-arc-gas (MIG) method differ greatly from those of the tungsten-inert-gas (TIG) welding operation, and hence the use of the incorrect gas would have a detrimental effect on the quality of the arc weld.
- Getting started with MIG welding is quicker and easier than with other welding methods.
- TIG welding, in contrast to MIG welding, is not required to employ filler metal in the welding supply.
- To prevent contamination of the welding region, an inert gas is employed during the procedure.
- Argon and helium are two examples of common inert gases used in TIG welding.
- In tungsten inert gas welding, a tungsten electrode is used to conduct electricity between the two metal pieces.
- By learning what kinds of jobs MIG and TIG welds excel at, you can determine which one to utilise for your personal project.
- Examining your project's end goals and the steps leading up to them will help you determine the path that will get you there most efficiently.
- Think about how much welding experience you have, the materials you'll be using, how much time you have, and how much money you have available.
- SPEEDCompared to TIG, MIG welding is much quicker.
- In addition to being more economical, the MIG welding process is significantly faster.
- The MIG welding gun is easier to use for beginners because it only requires one hand.
- As a rule, MIG welding is the prefered method due to its simplicity.
- MIG welding is quicker and better for thicker metals than TIG welding.
- The thickness of the object.
- MIG welding is faster than TIG welding, even on thicker metals.
- MIG welding can be done on a wide variety of metals.
- Which type of welding you use may depend on the scope of your project.
- Since an electric arc is formed between the electrode and the base plates during both TIG and MIG welding, the faying surfaces are melted and the plates are welded together.
- In both circumstances, inert shielding gas is employed to prevent the oxidation and contamination of the hot weld bead.
- There's a lot of room for creativity when it comes to the shape of a TIG torch.
- Clamping backing bars to the back of the welded item.
- Considering the benefits and drawbacks of MIG and TIG welding in light of your specific project is essential.
- Deposition of rust is possible using this technique.
- Accuracy - Compared to MIG welds, TIG welds offer a greater degree of accuracy and overall superior quality.
- The TIG method is more eco-friendly and produces fewer emissions.
- TIG welds require less upkeep than MIG welds since the welding electrode is not used up throughout the welding process.
- TIG CONSAs a slower process with lower deposition rates, TIG welding is more expensive than MIG welding.
- Required Clean Surface - Prior to beginning this procedure, the welding surface must be cleaned properly.
- TIG welding is more complex to accomplish, hence it demands a more skilled operator.
FAQs About Metal
Control: TIG welders need to have experience with timing and balancing materials in both hands. MIG is typically easier to control and is better for beginners. Costs: TIG is a more expensive method than MIG welding.
During MIG welding, a continuously-fed electrode wire and shielding gas feed into the welding area via a hand-held MIG torch. With TIG welding, the torch holds a consumable tungsten electrode and shielding gas is fed over this through a supply line.
MIG—i.e., metal inert gas—welding is generally used for large and thick materials. It employs a consumable wire that acts as both the electrode and the filler material. Compared to TIG welding, it is much faster, resulting in shorter lead times and lower production costs.
Precision. TIG welding can achieve this level of precision because the operator has more control over the gun vs. MIG welding. Unlike the MIG gun, which contains both the electrode and filler metal in one system, TIG welding uses a non-consumable tungsten electrode to form the arc.
While it's technically impossible to MIG weld without gas, it's very possible to weld without lugging a gas cylinder and other equipment around. Self-shielding welding with flux core wire is a great option for many hobby users, and with the right welding supplies you can achieve great results!