Can a Mig Welder Be Used for Stick Welding
No, a Mig welder cannot be used for stick welding.
Stick welding requires a constant current (CC) output, while a Mig welder produces a constant voltage (CV) output.
It is important to use the correct type of output for each specific welding process to ensure consistent results.
Did You Know?
1. The first successful commercial use of a MIG (Metal Inert Gas) welder can be traced back to the 1940s, as it was primarily developed for use in the aircraft industry during World War II.
2. Although MIG welders are commonly associated with welding thin sheets of metal, they can also be used for stick welding (shielded metal arc welding) by simply replacing the MIG welding gun with a stick welding electrode holder.
3. One advantage of using a MIG welder for stick welding is that it allows for faster electrode changes, which can be beneficial when working on small projects that require different types of electrodes.
4. MIG welders are typically easier to learn and use compared to stick welders, making them a popular choice for beginners in the world of welding.
5. While MIG welding is known for its speed and efficiency, stick welding is usually preferred for outdoor or windy conditions, as the stick electrode’s flux coating provides better protection against atmospheric contaminants.
Two Fundamentally Different Welding Power Sources
When it comes to welding, there are two fundamentally different types of welding power sources – those that produce a constant current (CC) output and those that produce a constant voltage (CV) output. These power sources are designed to meet the specific needs of different welding processes.
The Shielded Metal Arc Welding (SMAW) process, also known as stick welding, and the Gas Tungsten Arc Welding (GTAW) process, also known as TIG welding, require CC output from the power source. These manual processes rely on a consistent current to achieve the desired weld quality.
On the other hand, the Gas Metal Arc Welding (GMAW) process, also known as MIG welding, and the Flux Cored Arc Welding (FCAW) process, also known as flux core welding, require CV output. These semi-automatic processes rely on a consistent voltage to ensure a stable arc and proper metal transfer.
- CC output is needed for SMAW (stick welding) and GTAW (TIG welding)
- CV output is required for GMAW (MIG welding) and FCAW (flux core welding)
“Some welding processes, like SMAW and GTAW, require a constant current (CC) output, while others, like GMAW and FCAW, rely on a constant voltage (CV) output for optimal results.”
The Importance Of CC And CV Output In Welding Processes
The choice between CC and CV output is crucial for achieving the desired results in welding processes.
- Stick and TIG welding require CC output, while wire welding processes like MIG and flux core welding rely on CV output.
In stick welding, maintaining a constant current is essential for achieving a consistent melt-off rate. The voltage, on the other hand, varies with changes in arc length. This combination allows the stick welder to control the depth of penetration and the heat input into the base metal.
In wire welding processes, a constant voltage ensures better control over the welding parameters. CV output allows for stable arc conditions and ensures proper metal transfer, while varying the current and wire feed speed to achieve the desired weld characteristics.
- CC output is essential for stick and TIG welding
- CV output is crucial for MIG and flux core welding.
Automation And The Recommended Output For Different Welding Processes
Automation has revolutionized the welding industry, providing increased efficiency and precision. However, it requires constant control of variables to ensure consistent and high-quality welds. This is where the choice between CC and CV output becomes critical.
For automated GTAW, or TIG welding, CC output is recommended. The constant current ensures precise control over the welding process, allowing for accurate heat input and penetration depth in automated applications.
On the other hand, automated GMAW, or MIG welding, and FCAW, or flux core welding, require CV output. The constant voltage provides stability to the arc and allows for accurate control over wire feed speed and current. This combination ensures consistent weld quality in automated applications.
Submerged Arc Welding (SAW), typically an automated process, can utilize either CC or CV output, depending on factors such as electrode diameter, travel speed, and the size of the weld puddle. This versatility allows for customization of the welding process based on specific requirements.
- CC output is recommended for GTAW (TIG welding)
- CV output is required for GMAW (MIG welding) and FCAW (flux core welding)
- SAW can use either CC or CV output, depending on specific factors.
“The choice between CC and CV output is critical for maintaining consistent and high-quality welds in automated applications.”
Suitcase-Style Wire Feeders And Their Unique Features
- Suitcase-style wire feeders are designed for field welding applications, offering portability and versatility.
- These wire feeders have three unique features that set them apart from traditional wire feeders.
- Firstly, the wire is enclosed inside a hard plastic case, ensuring protection and preventing any damage during transportation or use in challenging environments.
- Secondly, they don’t require a control cable for the drive motor. This eliminates the need for additional cables, simplifying setup and improving efficiency.
- Lastly, suitcase-style wire feeders can operate with CC power sources, although with limited success. Wire welding with CC output works well with gas-shielded flux-cored (FCAW-G) and GMAW processes in spray arc or pulse spray arc modes. However, it performs poorly with self-shielded flux cored (FCAW-S) and GMAW processes in short-circuit transfer mode.
The Impact Of Output Type On Wire Welding Processes
The choice of output type, CC or CV, has a significant impact on wire welding processes. Generally, higher voltage processes operate better with CC output.
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Gas-shielded flux-cored (FCAW-G) and GMAW processes in spray arc or pulse spray arc modes work well with CC output. The combination of constant current and voltage variations allows for stable arc conditions and proper metal transfer.
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However, self-shielded flux-cored (FCAW-S) and GMAW processes in short-circuit transfer mode do not perform well with CC output. The lower voltage and constant current lead to inconsistent arc conditions and poor weld quality.
In conclusion, a MIG welder cannot be used for stick welding due to the fundamentally different welding power sources required for each process. Stick welding relies on a constant current (CC) output, while MIG welding requires a constant voltage (CV) output. Full automation in welding processes necessitates precise control of variables, recommending CC output for automated GTAW and CV output for automated GMAW and FCAW.
- Suitcase-style wire feeders offer unique features for field welding applications but are limited in their success with CC power sources.
The choice of output type significantly impacts wire welding processes, with higher voltage processes generally operating better with CC output.
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Frequently Asked Questions
Is a MIG weld as strong as a stick weld?
While MIG welding is preferred for its speed and ease of use, stick welding tends to yield stronger joints. This is because stick welding is capable of providing deeper weld penetration, resulting in a more resilient bond. However, it is worth noting that the strength of a weld also depends on various factors such as the technique used, the skill of the welder, and the specific application at hand.
What type of welder do I need for stick welding?
When it comes to stick welding, the type of welder you need depends on the specific requirements of your welding projects. If you are engaging in DIY welding tasks and don’t require excessive power, an AC stick welder could suffice. However, if you anticipate working on projects that demand higher power levels, a DC stick welder would be a more suitable choice. Considering the extent of power needed will allow you to select the appropriate welder for your stick welding endeavors.
What is MIG welding not good for?
Although MIG welding is versatile and efficient for welding thin metals, it may not be the best choice for applications that require welding thicker steel. Due to its limitations in delivering sufficient penetration, MIG welding may result in weaker welds and compromise the overall structural integrity of the thicker steel. Additionally, the replacement of the shielding gas bottle can be time-consuming and may hinder the welding process, causing interruptions and potential disruptions in workflow.
Can you weld anything with a MIG welder?
While MIG welding offers versatility, it does not mean that it is suitable for welding any material. MIG welding is ideal for metals such as aluminum, carbon steel, copper, stainless steel, magnesium, nickel, and bronze, which range in thickness from 24-gauge to 1/2-inch. Although MIG welding can also work with other alloys and combination metals, it is important to consider the specific properties of the material before attempting to weld it. Compatibility between the MIG welder and the metal being welded must always be evaluated to ensure optimal weld quality and adherence.
