A hybrid Super-MIG welding system.

MIG welding is the most common welding process found in fabricating shops.

While it has been around since the early 1940s, MIG welding has evolved to accommodate two forces:

• First, MIG welding has been expanded to include an increasingly broad range of materials and applications.
• Second, welders have searched for ways to reduce the costs of consumables and maintenance and set-up for the MIG process.

The goal of either of these does not exclude the other, and together, they are the reasons that MIG welding is so popular today. And they are the forces that continue to drive advances in the process.

For example, Thermadyne Industries Inc. has just introduced its Synergic Pulse MIG welding process that the company said links pulse welding parameters to wire feed speed to achieve optimum welding conditions across the full range of wire feed speed for a given wire size.

“The welding pulse profile is a combination of pulse height, pulse width, pulse frequency and background power. All these parameters are linked via the micro-processor to give the correct energy,” the company said.

Thermal Arc, one of Thermadyne’s product brands, recently introduced this digital welding technology in its PowerMaster SP and Power- Master SP Automation MIG welding packages.

Wes Morgan, global communications manager for Thermadyne, said the Synergic Pulse technology is leading the MIG welding industry in the United States and Canada because it is based on fully digital microprocessors that are designed to provide weld control with intelligent pulsing and synergic wave designs. That allows the company’s MIG welding equipment to produce precise, repeatable welds on nearly any material type from thin gauge to plate, Morgan said.

The intelligent, synergic One Touch Control microprocessor simultaneously links control of the wire feed, arc current and voltage to ensure a clean TIG-like weld with GMAW productivity, delivering perfect welding parameters for Smart- Mig (synergic non-pulse), PulseMig and Twin- Pulse welding over a wide range of different gas/ sire/material thickness combinations, he said.

The machines are pre-programmed with as many as 100 market optimized filler metal and shielding gas combinations and additional capacity for 100 separate user defined programs or jobs. The combination of those features has developed into a new class of welding power sources, Thermal Arc said.

Versatility in MIG machines also comes from Thermal Arc’s new Fabricator 281 that is designed for medium-duty welding applications, and provides more on-the-job freedom, the company said. The difference in these machines lie in their wire feeder systems that are separated from the power source that is equipped with an extra 26 feet of cable. This allows for a larger area of reach without having to move the entire machine, making it ideal for small fabricating shops.

The separation also allows for the work to be done at a greater distance from the main power source. This decreases the risk of injury from any kind of break or damage that could occur to input power wiring in a work environment, Morgan said.

“Versatility is a key component to the new Fabricator 281. The machine’s wide amp output allows welding with 0.023 in. to 0.045-in. solid wire and 0.030 in. to 0.035-in. flux cored wires,” Morgan said, adding that, when the spool gun is attached to the wire feeder, the user can switch between aluminum to mild steel with no downtime. Lastly, the Fabricator 281 is built on wheels to make it more portable. The machine is sold with a standard Tweco MIG gun.

MIG welding provides deep penetration.

MIG welding has also taken a leap forward with the special Super-MIG hybrid welding system, from Welding Solutions Inc..

This system combines two reliable standard welding processes – plasma arc and MIG arc – into one hybrid process, making it capable for most standard MIG, plasma and laser welding applications. This provides an advantage particularly for the small fabricating shop that might require a variety of processes, but doesn’t have the resources to put in all the various types of equipment required.

For example, Super-MIG can be used to do true overlap welds – continuous or stitch/spot configurations.

Ray Davis, sales and marketing manager for Welding Solutions Inc., said Super- MIG has been able to achieve welding speeds as much as two times faster than conventional MIG welders.

The interface and torch are patented by Plasma Laser Technologies and are designed to be integrated with any of the most commonly used MIG welding systems such as those made by Lincoln Electric Co., Miller Electric Co., Panasonic Co., OTC Daihen Inc. and ESAB Welding and Cutting.

By introducing a plasma electrode into the MIG welding process that establishes an arc at the leading position of the welding process, a “keyhole” is created within the parent material to eliminate the arc start delay and reduce the arc start failure mode. The company said that results in deeper penetration. The MIG arc that accompanies the plasma electrode operates in the “conduction” welding mode to fill the void created by the plasma arc.

MIG has been adopted for automation.

The Super-MIG process includes an interface that is compatible with most robot controllers and is capable of storing multiple welding programs, a Super-MIG torch, and the Super-MIG torch cleaning station that is designed to work automatically within a robotic welding cell.

It also can be used to weld standard industrial grade steels, stainless steel, high strength coated metals and titanium. Davis said a Super-MIG system for aluminum welding is under development.

More and more shops are automating some jobs, in part to offset the shortage of welders.

To help lower the overall expense of automated MIG welding, Tregaskiss has come out with its next generation Tough Gun Reamers, featuring longer-lasting, maintenance- friendly technology. The reamer quickly cleans and removes spatter from the MIG welding nozzle to ensure long consumable life, good gas coverage and reliable arc starts, said company information.

Tregaskiss pointed out that the new features include durable, internally mounted valves and seals around points of entry to protect against contaminants that could lead to costly replacement or repairs.

External setup switches also are sealed and allow for independent operation of the sprayer and spindle to expedite manual setup of the reamer. The check valve on the sprayer is now electrically operated to ensure more consistent performance.

To expedite routine maintenance and lower downtime costs, Tregaskiss noted that it has incorporated a hinged access door that allows internal components to be reached without tools. The addition of quickdisconnect wiring allows replacement of worn valves without rewiring, and a quick-change base plate allows the reamer to be removed and replaced quickly and accurately.