Mig Welding is not a difficult process to master, but unless you get the basics right, it can be torturously frustrating! These 10 Tips to improve your Mig Welding help.
Ensure your Mig Welder is in good working order; by that I mean making sure the Torch and Work Return (Earth), lead connections are clean and good. Make sure the Torch end parts are in good condition. Also check the Work Return (Earth) clamp is in good clean condition.
Check your Welding Wire is in good condition, if it’s rusty or dirty you should pull off the imperfect wire and discard it, because poor quality wire will lead to poor quality welds!
Check your Welding Wire Spool turns easily on the Spool Holder. It should have a little friction so it doesn’t overrun when the motor stops pulling the wire, but it shouldn’t be stiff to turn. Some spool Holders are adjustable, some are not. All can get dirty and cause jamming, so make sure the Holder is clean so the Spool turns smoothly.
Check you Wire Feed Rollers are clean and in good condition, because Rollers in poor condition will lead to erratic wire feeding and therefore poor quality welds. The Tension of the Rollers is VERY important. I’ve written a separate article on How to Adjust Mig Welder Wire Feed Roller Tension and produced a Video (bottom of linked page), do please check these out.
Place your Work Return (Earth) Clamp onto one of the pieces of metal you will be welding. Ensure the Clamp faces are clean and the metal you’re clamping onto is clean, because this is an electrical connection that is part of the welding circuit, so a good, clean connection is important!
Ensure the weld area of the parts to be welded are clean and free of surface contaminants, including rust, because if you weld over contaminants, they will end up in the weld!
Angle your Torch at approximately 70⁰, pointing in the direction you are going to move. In other words, you need to Push the torch, NOT Drag it!
Initially “Tack” the metal together with a short burst of welding, a tack every 50-75mm should be sufficient in most cases.
When running the weld, move as smoothly as possible, I find either resting my torch arm on my other arm, or putting down a finger for steadying is a BIG help.
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Hi Clarke
Some Spatter is a largely unavoidable feature of Mig Welding. Spatter can be reduced by ensuring the Wire Feed Speed is correctly balanced to the power that’s been set, I’ve written a separate article on Setting Wire Feed Speed also:
> Make sure the metal to be welded is as clean as realistically possible.
> Ensure your Work Return (Earth) Clamp is on clean metal and ideally, one of the pieces of metal being welded.
> Keep the end of your Gas Shroud/Nozzle around 10-12mm from the job.
In answer to the Gas question, YES, you need gas all the time, unless you’re using Self Shielding (Gasless) Wire.
Hope that helps
Cheers Graham
Sorry Graham, but you say in the narrative that you must push the weld, in other words if the torch is angled at 20 degrees to the right of vertical, then you would move the torch to the left. But in one of your answers to Nick, you say that the torch must be dragged/pulled.
Hi David
It seems I had a “Senior Moment” when I replied to Nick, Mig Torch should be Pushed (so as you describe). Thanks for pointing that out, I’ve corrected my comment to Nick.
Cheers
Graham
Thanks for a clear set of tips. Doesn’t having the torch at 20 degrees and pushing mean it’s harder to see where to go? Why push the weld rather than pull? Cheers
Hi Nick
If you pull the Torch you will create a larger/taller weld and have less penetration. This can be desirable, when Hardfacing for example, but in most cases, pushing the Torch will produce more desirable welds.
Hope that helps
Cheers
Graham
Tech question Graham… I’m using a Cigweld 135 setup, and just wondering why the requirement to change polarity when changing from flux core wire to solid wire/shielding gas?
Regards
Murray
Hi Murray
Two Thirds of the heat developed by a DC Arc is generated on the Positive Side and one Third on the Negative side. Self Shielding Flux Cored wire would overheat if run DC+.
Hope this helps.
Graham
G’day Graham,
Came across your site whilst searching for advice on gas V “gas less” mig welding. By far the best info I found on that subject and welding in general.
Great stuff, much appreciated!
Regards,
Murray
Hi Murray
Many Thanks for your generous comments. Everyone here works hard to offer the best possible Service & Support for both our customers, and the wider welding community, so it’s nice to know it’s appreciated.
A copy of your comments has been circulated to all relevant staff.
Best Regards
Graham
Hi Jeremy
Apologies for the confusion, 70⁰ from the work surface, or in other words, 20⁰ from Vertical.
Hope this clears it up for you. I will see if I can find a picture to insert!
Regards
Graham
Why do I get splatter when iam welding do I need to use gas all the time it’s spots of weld all around the piece .
Hi Clarke
Some Spatter is a largely unavoidable feature of Mig Welding. Spatter can be reduced by ensuring the Wire Feed Speed is correctly balanced to the power that’s been set, I’ve written a separate article on Setting Wire Feed Speed also:
> Make sure the metal to be welded is as clean as realistically possible.
> Ensure your Work Return (Earth) Clamp is on clean metal and ideally, one of the pieces of metal being welded.
> Keep the end of your Gas Shroud/Nozzle around 10-12mm from the job.
In answer to the Gas question, YES, you need gas all the time, unless you’re using Self Shielding (Gasless) Wire.
Hope that helps
Cheers Graham
Sorry Graham, but you say in the narrative that you must push the weld, in other words if the torch is angled at 20 degrees to the right of vertical, then you would move the torch to the left. But in one of your answers to Nick, you say that the torch must be dragged/pulled.
Hi David
It seems I had a “Senior Moment” when I replied to Nick, Mig Torch should be Pushed (so as you describe). Thanks for pointing that out, I’ve corrected my comment to Nick.
Cheers
Graham
Thanks for a clear set of tips. Doesn’t having the torch at 20 degrees and pushing mean it’s harder to see where to go? Why push the weld rather than pull? Cheers
Hi Nick
If you pull the Torch you will create a larger/taller weld and have less penetration. This can be desirable, when Hardfacing for example, but in most cases, pushing the Torch will produce more desirable welds.
Hope that helps
Cheers
Graham
Great tips! Agreed, proper maintenace of the MIG welder components is super important for performance. Thank you for the article!
Hi James
Thanks for the comment, glad you found the article useful.
Cheers
Graham
I am studying MIG welding for a couple of days now and I am grateful that I have found some great tips here. Thanks a lot!
Hi Paul
Good to hear you found the article useful.
Regards
Graham
Tech question Graham… I’m using a Cigweld 135 setup, and just wondering why the requirement to change polarity when changing from flux core wire to solid wire/shielding gas?
Regards
Murray
Hi Murray
Two Thirds of the heat developed by a DC Arc is generated on the Positive Side and one Third on the Negative side. Self Shielding Flux Cored wire would overheat if run DC+.
Hope this helps.
Graham
G’day Graham,
Came across your site whilst searching for advice on gas V “gas less” mig welding. By far the best info I found on that subject and welding in general.
Great stuff, much appreciated!
Regards,
Murray
Hi Murray
Many Thanks for your generous comments. Everyone here works hard to offer the best possible Service & Support for both our customers, and the wider welding community, so it’s nice to know it’s appreciated.
A copy of your comments has been circulated to all relevant staff.
Best Regards
Graham
Excellent guide thanks
Thanks for the comment David, much appreciated. Glad you found it useful.
Kind Regards
Graham
Graham – Is that 70 degrees to the work or to the vertical (the work I think but I’d like it confirmed).
Hi Jeremy
Apologies for the confusion, 70⁰ from the work surface, or in other words, 20⁰ from Vertical.
Hope this clears it up for you. I will see if I can find a picture to insert!
Regards
Graham
Good tips helpful for the beginner
Thanks for the comment Jason, glad you found the article useful.
Kind Regards
Graham