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This material is copyright - all rights reserved. Reproduced under licence from The Steel Construction Institute on 12/2/2007 To buy a hardcopy version of this document call 01344 872775 or go to http://shop.steelbiz.org/ Steel Designers' Manual - 6th Edition (2003) 698 Welds and design for welding e •• a • Fig. 24.7 Manual metal-arc welding of structural components (Photograph courtesy of The Lincoln Electric Company) known as ‘stick’ welding. MMA equipment is widely available and inexpensive in comparison with other processes. A typical MMA electrode, which usually has a length in the range of 230–460 mm, is held firmly in tongs or holders that are connected by flexible cables to the power source, which may be a transformer, rectifier, inverter, or engine-driven generator, as shown in Fig. 24.7. The electrode coating melts in the arc and (1) protects the weld metal from the surrounding air, (2) forms a slag that protects and supports the weld metal, and (3) usually adds alloying elements to the weld metal. 24.4.3 MIG/MAG welding MIG/MAG welding wire is generally copper-coated to provide good electrical contact with tip in the welding gun. The majority of MIG/MAG wires contain sufficiently high levels of silicon and manganese to prevent porosity that would be caused by oxygen that enters the weld metal from the active shielding gases used. A limited range of low-al1oy wires is available for high strength and toughness applications. • • -
This material is copyright - all rights reserved. Reproduced under licence from The Steel Construction Institute on 12/2/2007 To buy a hardcopy version of this document call 01344 872775 or go to http://shop.steelbiz.org/ Steel Designers' Manual - 6th Edition (2003) The essential components of equipment for MIG/MAG welding are the handheld gun (or mechanized welding head) through which the continuous wire is fed into the arc, the wire feeder, and a constant-voltage welding power source, as shown in Fig. 24.8. The continuous nature of the process allows it to be used for semiautomatic, mechanized, automatic, and robotic welding. The arc conditions (voltage and current) are controlled mainly by the equipment, giving rise to the use of the term semi-automatic welding. The MIG/MAG welding gun feeds the wire, conducts the current and delivers a gas shield. The wire leaves the gun from a copper contact tube, which is surrounded by a concentric gas nozzle.All components of the gun should have adequate currentcarrying capacity and be tightly connected to provide good electrical and thermal conductivity. The wire feeder, fitted with V-grooved rolls for solid MIG/MAG wire or knurled rolls for cored and submerged arc wires, pulls the wire from a spool or drum and pushes it through the cable (or welding head on a mechanized machine) to the gun. 24.4.4 Cored wire welding Welding processes 699 Fig. 24.8 MIG/MAG welding – note the rectifier power source and feeder spool of welding wire behind the welder (Photograph courtesy of The Lincoln Electric Company) Cored wire welding is a modification of MIG/MAG welding in which the electrode wires are hollow steel tubes filled with powders. Cored wires have some specific
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