How to Guide for Gasless MIG Welding

Gasless MIG welding, also known as flux-cored arc welding (FCAW)

Gasless MIG welding is a versatile and efficient welding process that doesn’t require external shielding gas. This makes it ideal for outdoor welding projects or situations where portability is essential. In this guide, we’ll walk you through the steps and techniques for mastering gasless MIG welding, from equipment setup to executing perfect welds.

Read to the end and see the Seven Essential Gasless Mig Welding Tips.

Understanding Gasless MIG Welding

What is Gasless MIG Welding?

Gasless MIG welding uses a flux-cored wire that generates its own shielding gas when heated. This eliminates the need for an external gas supply, making the process simpler and more portable.

Advantages of Gasless MIG Welding

1. Portability: No need for gas cylinders.
2. Wind Resistance: Effective in outdoor conditions where wind might blow away shielding gas.
3. Ease of Use: Simplified setup compared to traditional MIG welding.

Applications of Gasless MIG Welding

Ideal for:

• Outdoor welding
• Automotive repairs
• Farm equipment maintenance
• Construction projects

Essential Equipment

Welding Machine

Choose a MIG welder compatible with flux-cored welding. Ensure it has adjustable settings for voltage and wire feed speed.

Flux-Cored Wire

Select the appropriate flux-cored wire for your project. Common types include E71T-11 and E71T-GS, suitable for mild steel.

Protective Gear

Always wear:

• Welding helmet with an auto-darkening lens
• Welding gloves
• Flame-resistant clothing
• Safety glasses
• Respirator or welding fume mask

Additional Tools

• Wire brush or grinder for cleaning the metal
• Clamps to secure workpieces
• Welding pliers for handling hot materials

Preparation

Setting Up Your Workspace

1. Clean the Area: Remove any flammable materials and ensure proper ventilation.
2. Lighting: Ensure adequate lighting to see the weld area clearly.
3. Safety Measures: Have a fire extinguisher nearby and ensure your workspace is free of tripping hazards.

Preparing the Metal

1. Clean the Surface: Use a wire brush or grinder to remove rust, paint, or oil from the metal surface.
2. Fit-Up: Securely clamp the workpieces together to prevent movement during welding.

Machine Setup

Adjusting Voltage and Wire Feed Speed

1. Voltage: Set the voltage according to the thickness of the metal. Higher voltage for thicker metals, lower for thinner metals.
2. Wire Feed Speed: Adjust the wire feed speed to match the voltage setting. Too fast or too slow can result in poor welds.

Polarity Setting

For gasless MIG welding, set your machine to DCEN (Direct Current Electrode Negative), also known as straight polarity.

Welding Technique

Striking an Arc

1. Hold the Torch: Position the torch at a 10-15 degree angle to the workpiece.
2. Contact Tip: Ensure the contact tip is close to the metal without touching it.
3. Trigger: Squeeze the trigger to start the arc and begin welding.

Travel Speed and Angle

1. Travel Speed: Maintain a consistent speed. Too fast results in weak welds, too slow causes excessive buildup.
2. Torch Angle: Keep the torch angled slightly towards the direction of travel.

Weaving Technique

For thicker metals, use a slight weaving motion to ensure proper penetration and a wider bead.

Welding Position

1. Flat Position: Best for beginners, provides better control.
2. Horizontal and Vertical Positions: Requires more skill, adjust settings and technique accordingly.
3. Overhead Position: Most challenging, ensure proper safety and control.

Post-Weld Process

Cleaning the Weld

1. Slag Removal: Use a chipping hammer and wire brush to remove slag from the weld bead.
2. Inspect the Weld: Check for defects such as porosity, cracks, or incomplete fusion.

Finishing

Grind or polish the weld if needed, especially if the appearance is important or if further work is required on the welded piece.

Common Issues and Troubleshooting

Porosity

• Cause: Contaminants or improper settings.
• Solution: Clean the metal thoroughly and adjust voltage/wire speed.
• What is weld porosity? See Porosity in Welding.

Inconsistent Bead

• Cause: Uneven travel speed or incorrect settings.
• Solution: Practice maintaining a steady hand and adjust settings accordingly.

Spatter

• Cause: High voltage or wire feed speed.
• Solution: Lower the voltage or wire feed speed.

FAQs

1. What is the best flux-cored wire for beginners? E71T-11 is a popular choice for beginners due to its versatility and ease of use on mild steel.

2. Can I use gasless MIG welding indoors? Yes, but ensure proper ventilation to avoid inhaling fumes.

3. How do I reduce spatter in gasless MIG welding? Adjusting the voltage and wire feed speed can help reduce spatter. Ensuring clean metal surfaces also minimizes spatter.

4. What is the ideal torch angle for gasless MIG welding? A 10-15 degree angle towards the direction of travel is ideal for most welds.

5. How often should I replace the contact tip? Replace the contact tip when it shows signs of wear or if the arc becomes unstable, typically after several hours of welding.

Seven Essential Gasless Mig Welding Tips

1. Dial in the Polarity:

Unlike traditional MIG welding, gasless MIG uses a different polarity setting. Ensure your welder is set to Direct Current Electrode Negative (DCEN). This setting provides the correct heat distribution for the self-shielding flux contained within the electrode wire. Using the wrong polarity can lead to excessive splatter and weak welds. If your welder doesn’t offer DCEN polarity, it might not be suitable for gasless welding.

2. Embrace the Drag Technique:

Unlike push welding used in solid wire MIG welding, gasless MIG requires a drag technique. In this method, you point the torch nozzle in the direction you’re welding, but drag the torch backwards at an angle of 10-15 degrees. This allows the flux coating to vaporize and shield the weld pool as you progress.

3. Fine-Tune Machine Settings and Technique:

Gasless MIG welders operate similarly to standard MIG welders in terms of adjusting settings. Consult your machine’s manual to determine the optimal voltage and wire feed speed for your material thickness. Practice on scrap metal to perfect your travel speed and torch angle before tackling your main project.

4. Fight the Filth:

Gasless MIG welding doesn’t offer the same level of shielding as gas-protected MIG. Therefore, ensuring clean metal surfaces is crucial. Wire brush or grind away dirt, rust, paint, and any contaminants from your weld area. Cleanliness minimizes the chance of introducing impurities into the weld pool, reducing weld strength and quality.

5. Tame the Breeze:

Wind can disrupt the flux shielding, leading to porosity (air pockets) in the weld. If possible, weld in a sheltered location or use wind guards to minimize airflow around the weld zone. For outdoor projects, choose a calm day for optimal welding conditions.

6. Upgrade Your Wire:

Not all flux-cored wires are created equal. Higher quality wires offer a smoother welding experience with less splatter and a more consistent weld profile. At Norsemen Safety & Welding Supplies, we offer a wide selection of top-grade flux-cored wires to match your specific project needs.

7. Safety First!

Always prioritize safety when welding. Wear proper Personal Protective Equipment (PPE) including a welding helmet, gloves, respirator, and flame-retardant clothing. Ensure adequate ventilation to avoid fume inhalation, and keep a fire extinguisher nearby in case of emergencies.

By following these tips and using the right equipment from Norsemen Safety & Welding Supplies, you’ll be well on your way to mastering gasless MIG welding and achieving professional-looking results on your next project.

Ready to get started? Browse our extensive selection of gasless MIG welders, flux-cored wires, and safety gear online and visit Norsemen Safety & Welding Supplies in Belfast! Welding Belfast, Welding Ireland and Welding UK – we’ve got you covered.