Welding is an integral part of ensuring that each of Marlin's bespoke wire baskets is up to fulfilling the customer's requirements. Welding entails more than simply applying heat to the basket wires and fusing them. For any particular metal shape, a wide variety of specialised welding methods are available.
Wire baskets' ability to withstand tension can be improved by employing the appropriate welding method. However, issues can arise from employing the incorrect welding procedure, including weaker bonding, corrosion of the weld joint, and the inability to complete the weld altogether.
Inert metal gas (MIG) and inert tungsten gas (TIG) welding are two of the most often employed welding techniques in Australian manufacturing facilities. There are certain parallels between the two arc welding processes, but each has its advantages. Which method, MIG or TIG, should be used and why? Check out Australian General Engineering
Table of Contents
What Is the Process of Using a MIG Welder?
The continuous metal wire is fed into the weld site during MIG welding, which stands for "inert metal gas" welding. Consumable welding wire is a filler substance to help fuse metal parts. Welding with this method is sometimes referred to as "GMAW" (Gas Metal Arc Welding).
The first step is for the engineering team at Marlin Steel to programme a MIG welding robot to weld the piece of metal. A woodblock cut on a routeing wood machine is commonly used to brace the joint and prevent the workpiece from shifting during the weld, which could otherwise impair the joint's angle. The robotic welder then swiftly and precisely rotates the welding arm to disperse the resulting heat.
MIG and TIG welding requires a distinct gas blend, while MIG welding requires a mixture of gases. Therefore, you shouldn't use pure helium or some other inert gas for shielding. This is because the filler-metal-arc-joining (MIG) method's arc properties are very different from those of the tungsten-inert-gas (TIG) welding operation. Hence, using improper gas would hurt the quality of the arc weld.
When welding is done, the MIG welder also needs to be cleaned thoroughly. Weld spatter is a common problem when employing filler material, and it can happen no matter how rapidly the welding equipment moves. Injuries can occur if spatter forms sharp edges, or "burrs," on the weld joint; sanding or electropolishing the area is sometimes necessary to get rid of these.
Nowadays, most welders prefer MIG welding over TIG welding. As a result, MIG welding can be learned more quickly and put into practice more quickly.
What Is the Function of a TIG Welder?
Tungsten inert gas welding (TIG) is a subset of gas tungsten arc welding (GTAW) (Gas Tungsten Arc Welding). An inert tungsten electrode, a computerised controller for timing welding processes, and a robotic arm assembly for positioning the welding tip are all components of a TIG welder. In contrast to MIG welding, the welding supply for TIG welding may or may not be a filler metal.
TIG welder machines, like MIG welding robots, can be pre-programmed to carry out the actual weld. Workers risk injury from sparks or filler material generated during TIG welding. Robots are designed to do the actual welding, while a human welder monitors the process for safety and consistency.
An inert gas is employed throughout the procedure to prevent any contamination of the welding region. TIG welding often makes use of inert gases such as argon or helium. The use of a filler is optional in TIG welding, unlike the MIG technique, but it is recommended for joining metals having high melting temperatures to avoid cracking.
TIG welding with direct material welding eliminates the need for post-weld finishing operations like electropolishing by eliminating weld spatter on the workpiece surface, which filler materials can cause.
In tungsten inert gas welding, an electric current is passed through the metals being joined using an electrode made of tungsten. Welding is accomplished by melting metal with an electrode and then manually dipping filler material into he resulting puddle.
Welding using a TIG torch takes two hands since the filler metal is held in a separate container. Nevertheless, TIG welding doesn't require any filler metal at all. In addition to the hand controls, TIG welders typically have a foot pedal that regulates the current flowing to the torch. Spatter is an unavoidable byproduct of several types of arc welding. Due to the lack of spatter, TIG welding produces a more polished appearance.
When Comparing MIG and TIG, What Are the Key Differences?
Depending on the circumstances, there are benefits and drawbacks to using both MIG and TIG welding. Consider your project's end goals and the steps leading up to them to choose the path that will get you there the fastest. Think about how much welding experience you have, the materials you'll be using, how much time and money you have, and how much you can spend.
Differences Between Metal-Inert-Gas (MIG) And Tungsten-Arc (TIG) Welding Include:
Diversity
MIG welding is better suited for your project for several reasons. First, there's a wider range of people represented. Second, TIG welding's versatility extends to a wider variety of metals, but it's not as efficient for thicker work. Aluminum, stainless steel, and steel in thicknesses ranging from 26-gauge metal sheets to thick structural plates are all suitable for MIG welding.
The wire feed serves as both an electrode and a filler in MIG welding, giving it a significant advantage over TIG. This allows for fusing thicker pieces without having to heat them through completely. Moreover, MIG welding may be employed to join dissimilar materials without requiring melting between them due to the use of filler.
Speed
MIG is more popular than TIG because of its faster welding time. Since a MIG gun can be left on for extended periods, it is more effective and productive than its alternative. MIG is the standard for high-volume manufacturing and other industrial applications. (It can also be easily automated). But, TIG welding is a more precise process that takes more time.
MIG welding is the most efficient option and is recommended for mass production. Compared to other methods, TIG takes longer but produces better-quality results.
Cost
The time and effort you put into a manufacturing job directly correlate to the bottom line. MIG welding is more cost-effective since it is faster than other methods. MIG parts, in addition, the availability and cost are far better than those of TIG.
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Ease
Furthermore, MIG welding is more intuitive and can be mastered with minimal time invested in training. You may start and stop the weld by pulling the trigger, earning it the nickname "hot glue gun" of welding. Because the MIG welding gun can be held and operated with a single hand, it is ideal for novice welders. In contrast, TIG welding is an intricate process that calls for utilising both hands and a single foot to perform distinct tasks.
MIG welding has been more commonly suggested than TIG welding because of its simplicity. Welding with this method is generally advised for novice welders and those without professional training because it is more forgiving than TIG welding.
However, TIG welding calls for precise management of the weld's time, pressure, and power source. Automatic CNC welding machines are ideal for TIG welding in most circumstances. Welds can be repeated with greater consistency and accuracy by a machine than by a human welder.
Whether you're using a MIG or TIG welder, getting the settings and controls precisely right is crucial to avoid making the same error over and over again.
Object Thickness
It takes less time for MIG to weld thick metals than for TIG. Therefore, TIG may be preferable to MIG when working with thin metal.
Any common metals can be welded using MIG technology. Metals, including aluminium, stainless steel, and mild steel, can be used. TIG welding can also be done with these metals, albeit it is more effective on thinner sheets.
Object Thickness. Compared to TIG welding, MIG's speed when working with thicker metals is far greater. Therefore, TIG may be preferable to MIG when working with thin metal.
The versatility of MIG welding means that it may be used on a wide variety of metals. Metals like aluminium, stainless steel, and more common mild steel are all viable options. Although TIG welding can be done with these metals, it performs best on thinner gauge materials.
Technique
The approach taken is the key differentiator between these two kinds of approaches. MIG welding is performed 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 feed filler material onto the weld.
Difficulty
Since MIG wire is fed in a steady stream, it requires less operator skill than TIG. TIG welding requires the welder to juggle two tools: the welding torch and the filler material.
Project Size
Which type of welding you use may depend on the scope of your project. MIG welds are ideal for longer, continuous runs of thicker metals in larger construction projects. TIG welds are preferred for smaller jobs and projects involving thinner metals due to their precision and cleanliness.
Control
The MIG welding process is more user-friendly and suitable for novices because it is less complicated. However, TIG welders need skills in timing or balancing materials in both hands.
Appearance
Many people adore the sleek, attractive appearance of TIG-welded pieces. Therefore, this welding method is frequently employed for decorative and artistic purposes due to its aesthetic appeal.
How Is MIG Welding Comparable to TIG Welding?
In both TIG and MIG welding, an electric arc is formed between an electrode and the base plates that melt the faying Surface and generate the coalescence, making both methods essentially arc welding techniques. In addition, due to the fusing of the base metals during the joining process, these techniques also fall under the umbrella of fusion welding.
Each method depends on the bare electrode. Even though the electrode material is now different, neither of these procedures requires a flux-coated electrode.
In any situation, extra supplies of shielding gas will be needed. In contrast, shielding gas is obtained naturally during the MMAW or FCAW process as the flux available with the electrode is disintegrated.
These processes include using inert shielding gas to prevent the oxidation and contamination of the hot weld bead. Gases such as argon, nitrogen, helium, or a combination of these are used as shielding exclusively.
Only conductive metals can be joined using either of these methods. True arc welding procedures can only be used on metals that conduct electricity. Welding in a solid state can be used to combine metals that do not conduct electricity. Check out Aluminium Welding: How to Weld Aluminium
In What Ways Does MIG Welding Work?
Power
Most of the time, a DC source with a steady voltage is used.
Wire
To provide consistent welds, the wire-feed mechanism must function properly. Pinch rolls, push-pull, and spool-on-gun are just a few feeding techniques available.
Electrode
You'll need the proper diameter and composition of your MIG weld, so be sure to check the specifications of your project before you start shopping.
Torch
The welding current is transferred from the wire to the arc via the gas the welding torch provides. Depending on the application, torches can be either air-cooled or water-cooled. Compared to their water-cooled counterparts, air-cooled torches are often more affordable and portable. The nozzle is cooled by the gas that is passing through it. These welding tools are best used for less intensive projects. When welding with a high current and doing tough work, a water-cooled gun is a way to go.
Conduit
For smooth feeding, make sure the pipe is both short and straight.
Metal Filler
It not only serves as a conductor of electricity to melt the electrode, but it also serves to reinforce the weld.
Insulation from Gases
Argon with carbon dioxide is commonly used in protective gas mixtures for the weld pool and arc.
Which Materials Make Up TIG Welding?
Power
AC or DC can be used as the power supply. Some welders will provide a toggle to select a favoured currency. For example, a metal like aluminium is more amenable to an AC power source. On the other hand, a powerful arc can be achieved with a DC power source; however, the workpiece must be cleaned first.
Torch
There's a lot of room for creativity regarding the look of a TIG torch. For example, the on/off switch and other controls may be included in the handle or accessible through a foot pedal.
Foot Pedal
The power of the torch can be adjusted in this way. Intensifying the arc's heat requires more pedal force because of the increased electricity flow. It shortens the welding time, but you need to know how to deal with the increased heat and velocity.
Gas and Electrode Shielding
The arc that creates the weld pool is formed based on the angle of the electrode tip. Therefore, 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. Most of the time, argon is used as a gas.
Material for Filling
A wide variety of materials and sizes are available for use as filler rods. The size of the filler rod is determined by the thickness of the material being welded.
Backing Bars
As opposed to letting the weld area cool naturally, this help speeds up the process. Clamping backing bars to a back of a welded item. Copper or aluminium can be used for a backing bar because of their different thermal conductivities. It is also possible to purchase a backing bar with a water cooling system that uses a constant cold water flow to cool the bar rapidly.
The Advantages and Disadvantages of MIG Versus TIG Welding Are Discussed.
As you weigh the benefits of MIG versus TIG welding for your project, it's important to remember the differences between the two.
Even if you prefer one type of welding method over another, it's important to weigh the pros and cons before making a final selection.
Check out The Ultimate Guide To Getting your Welding Certification
MIG Pros
- Welds may be made in less time with MIG.
- Cost-Effective - Compared to TIG welds, this method saves money, and the necessary equipment is easier to come by.
- MIG welding is more precise because it produces a stronger and more consistent weld.
- Less post-weld maintenance is needed. This technique yields a clean weld with minimal post-weld maintenance needs.
MIG Cons
- MIG welding is weaker than TIG because the filler metal used in MIG welding is smaller.
- Reduced arc stability and wire burn-back are two variables that reduce the reliability of this welding process.
- MIG welding is more dangerous since it generates more smoke, fumes, and sparks.
- Deposits of rust can form with this technique.
- Needed Thickness - MIG welds can melt through thin metals, so the adequate thickness is essential.
- Ambient Restrictions - The gases used make this technique impractical for usage in the open air.
- Although MIG welding is effective on a wide variety of metals, different types of metal have different wire and gas needs.
TIG Pros
- TIG welds are superior in quality and precision to MIG welds.
- The TIG method is more eco-friendly and produces fewer emissions.
- TIG welding eliminates the need for filler material.
- Improved Handling: The pedal can be utilised to regulate the temperature using the soles of your feet.
- TIG welds require less upkeep than MIG welds since the welding electrode doesn't get used up throughout the welding process. Although cleaning the electrodes between uses is the only real
- maintenance they require, they require less attention overall.
TIG Cons
- The cost of TIG welding is greater than that of MIG welding since it is a slower process with lower deposition rates. The welding deposition rate is expressed in pounds per hour deposited at a certain welding current.
- Clean Surface Necessary - The welding surface must be cleaned properly before beginning this process.
- TIG welding is more complex to conduct. Hence it demands a more experienced operator.
- More Effort and Time Consumption: The initial setup and the final welding stages take longer with this procedure.
If You’re Debating Between MIG and TIG Welding, Here’s When to Use Either.
Is there a time when one of these two welding methods would be preferable to the other?
The use of MIG or TIG welding by you could be the deciding factor in the success or failure of your project. You might significantly reduce production time while increasing product quality and longevity.
You can choose between MIG and TIG welds for your project if you understand the types of work best suited to each type of weld.
In general, the following should be taken into account while deciding between MIG and TIG welding:
How thick are the metals that will be linked together?
It is particularly inefficient to utilise TIG welding on thicker pieces or sheet metal because more energy is required to heat them to a melting point before they would fuse. Therefore, MIG welding could be preferable for particularly thick metals.
MIG welding is the way to go if your project involves thicker, larger metal components that require a lot of welding. The filler material on a spool that is supplied continually will be used to join your parts together. After the welding process, this type of welding may need to be ground or smoothed.
What’s the metal’s conductivity?
In addition, the ductility of the metal being linked is a factor to consider. The metal's intrinsic electrical resistance produces the heat required to fuse metal during an electric arc welding process as the electric arc attempts to pass through the weld spot. Heat transfer from the metal to the surrounding environment will be slower, so more energy will be required if the metal is very malleable. Metals with higher resistance to electrical current can be heated more quickly during welding, eliminating the need for filler metal.
Am I welding different metals?
Welding different metals isn't recommended, yet it's possible that doing so is necessary for some situations. It's best to utilise a welding method that uses a filler substance to build a bond between different metals. On the other hand, this filler material must be selected with caution.
Should the smoothness/condition of the surface matter?
Using filler materials raises the likelihood that weld spatter may be left on a workpiece's Surface, necessitating additional effort to smooth out if defect-free surfaces are a priority. Bypassing the need for filler material, direct metal-to-metal welding produces welds that are typically cleaner than those produced using filler metal alone.
Metal arc welding processes have clear advantages, and it's straightforward to determine which would work best for a given application. 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 best option appears clear.
Conclusion
Marlin Steel's custom wire baskets are made with careful attention to detail, including a variety of welding techniques. Both metal inert gas (MIG) and tungsten inert gas (TIG) welding see widespread use in Australia's factories. The MIG welding robot feeds a continuous metal wire, which acts as a filler substance to help fuse metal parts, into the weld site. The robotic welder quickly and precisely rotates the welding arm to disperse the resulting heat. Unlike TIG welding, which can use a single gas type, MIG welding calls for a combination of gases.
When using filler material, spatter is inevitable regardless of how quickly the welding equipment is being operated. Gas tungsten arc welding (GTAW) is a type of welding that employs an inert tungsten electrode, a computerised controller for timing welding processes, and a robotic arm assembly for positioning the welding tip. There is a greater chance of injury to workers from sparks or filler material generated during TIG welding than there is during MIG welding because the welding supply may or may not be a filler metal. Electropolishing and other post-weld finishing processes are not necessary when TIG welding is combined with direct material welding. There are many variations of welding techniques, each with its own advantages and disadvantages.
While TIG is more precise and takes more time, MIG is more popular because of its faster welding time and adaptability. Mass production scenarios call for MIG welding's superior efficiency. Because of its superior availability and lower price compared to TIG, it offers better value for the money. It's easier to pick up and use with little in the way of formal instruction. Due to its ease of use and tolerance for mistakes, MIG welding is typically recommended over TIG welding.
For the most part, TIG welding is best done with an automatic CNC welding machine. TIG welding requires the welder to juggle the welding torch and the filler material, while MIG welding is performed by continuously feeding an electrode wire through a spool gun. MIG welding is more user-friendly than TIG and is ideal for lighter metals and smaller projects due to its accuracy and cleanliness. Similar to TIG Welding in its aesthetic value, MIG Welding is a popular welding technique. A coalescence is produced by melting the ageing Surface via an electric arc formed between an electrode and the base plates.
Welding torches use either air or water to cool the gas that carries the welding current from the wire to the arc. Consistent welds require a well-functioning wire-feed mechanism, as well as confirmation that the weld is of the right diameter and composition. Protective gas mixtures for the weld pool and arc typically consist of argon and carbon dioxide. An AC power source is preferable for metals like aluminium, though DC power can be used if necessary. There is considerable leeway in terms of how a TIG torch is designed to look, and the torch's output can be adjusted with a foot pedal.
Filling components include filler rods, backing bars, and a water-based cooling system. It's important to weigh the benefits and drawbacks of MIG and TIG welding before deciding which method to use. Even though MIG welding is faster and cheaper than TIG welding, the latter is stronger overall due to greater arc stability and less wire burn-back during the welding process. When compared to MIG welding, TIG welding is more precise and durable, requires less maintenance, is better for the environment, and produces fewer emissions. It requires a more skilled operator and is more difficult to execute.
It's important to think about the tasks that each type of weld is best suited for when deciding between MIG and TIG welds. If your project calls for lots of welding of thick, large pieces of metal, MIG welding is the way to go. There are obvious benefits to using metal arc welding processes, and it's not hard to figure out which method would be ideal in a given situation. Even when it seems obvious that one course of action is best, the Marlin engineering team still uses virtual physics simulation software to verify their assumptions and guarantee the welded joint will behave as expected.
Content Summary
- Welding is an integral part of ensuring that each of Marlin's bespoke wire baskets is up to fulfilling the customer's requirements.
- Wire baskets' ability to withstand tension can be improved by employing the appropriate welding method.
- Inert metal gas (MIG) and inert tungsten gas (TIG) welding are two of the most often employed welding techniques in Australian manufacturing facilities.
- This is because the filler-metal-arc-joining (MIG) method's arc properties are very different from those of the tungsten-inert-gas (TIG) welding operation.
- Tungsten inert gas welding (TIG) is a subset of gas tungsten arc welding (GTAW) (Gas Tungsten Arc Welding).
- In contrast to MIG welding, the welding supply for TIG welding may or may not be a filler metal.
- In tungsten inert gas welding, an electric current is passed through the metals being joined using an electrode made of tungsten.
- Depending on the circumstances, there are benefits and drawbacks to using both MIG and TIG welding.
- Consider your project's end goals and the steps leading up to them to choose the path that will get you there the fastest.
- Think about how much welding experience you have, the materials you'll be using, how much time and money you have, and how much you can spend.
- Differences Between Metal-Inert-Gas (MIG) And Tungsten-Arc (TIG) Welding Include: DiversityMIG welding is better suited for your project for several reasons.
- But, TIG welding is a more precise process that takes more time.
- MIG welding is the most efficient option and is recommended for mass production.
- MIG welding is more cost-effective since it is faster than other methods.
- However, TIG welding calls for precise management of the weld's time, pressure, and power source.
- Whether you're using a MIG or TIG welder, getting the settings and controls precisely right is crucial to avoid making the same error over and over again.
- It takes less time for MIG to weld thick metals than for TIG.
- Any common metals can be welded using MIG technology.
- Compared to TIG welding, MIG's speed when working with thicker metals is far greater.
- In both TIG and MIG welding, an electric arc is formed between an electrode and the base plates that melt the faying Surface and generate the coalescence, making both methods essentially arc welding techniques.
- True arc welding procedures can only be used on metals that conduct electricity.
- Welding in a solid state can be used to combine metals that do not conduct electricity.
- TorchThe welding current is transferred from the wire to the arc via the gas the welding torch provides.
- Argon with carbon dioxide is commonly used in protective gas mixtures for the weld pool and arc.
- TorchThere's a lot of room for creativity regarding the look of a TIG torch.
- A gas lens for gas flow via the torch nozzle is required for arc and weld pool protection.
- Clamping backing bars to a back of a welded item.
- As you weigh the benefits of MIG versus TIG welding for your project, it's important to remember the differences between the two.
- MIG Pros Welds may be made in less time with MIG.
- Cost-Effective - Compared to TIG welds, this method saves money, and the necessary equipment is easier to come by.
- Although MIG welding is effective on a wide variety of metals, different types of metal have different wire and gas needs.
- TIG Pros TIG welds are superior in quality and precision to MIG welds.
- The TIG method is more eco-friendly and produces fewer emissions.
- TIG Cons The cost of TIG welding is greater than that of MIG welding since it is a slower process with lower deposition rates.
- More Effort and Time Consumption: The initial setup and the final welding stages take longer with this procedure.
- You can choose between MIG and TIG welds for your project if you understand the types of work best suited to each type of weld.
- It's best to utilise a welding method that uses a filler substance to build a bond between different metals.
- Bypassing the need for filler material, direct metal-to-metal welding produces welds that are typically cleaner than those produced using filler metal alone.
FAQs About Weddings
TIG welding is often considered the strongest weld since it produces extreme heat and the slow cooling rate results in high tensile strength and flexibility.
The most important applications for TIG welding are pipeline and pipe welding. It is, however, used in many industries, such as aviation and aerospace and sheet metal industries, when welding particularly thin materials and special materials such as titanium.
Material thickness: Most reputable MIG machines can be used to weld aluminium down to 3mm thickness. To successfully weld materials thinner than 3mm, it may be necessary to use specialist MIG or TIG welders with pulse capability.
Whether you use the standard torch or a spool gun, MIG welding aluminium requires pure argon gas.
Tungsten Inert Gas welding, or Gas Tungsten Arc Welding, is the safest and most efficient ways to weld aluminium. It is possible to weld with a MIG welder, but only if the sheet of aluminium is unusually thick, as the MIG welder is designed for thicker metal sheets.