Thirty weld questions for you to figure out how
MIG weld process control expertise
for your company and for your career.
 Welding a common 1/16 (1.6 mm) sheet metal duct. Provide what you believe is the optimum,
Short Circuit wire feed setting, weld current and voltage with an 0.035 (1mm)
wire and 80 argon - 20 - 25% CO2?.
Wire feed___ Amps.____ Volts____
 You are using an 0.035 (1mm) MIG wire and argon - 20% CO2 gas mix. You have to set robot parameters
to weld 0.080
(2 mm) gage parts. For the lap welds, what MIG weld transfer mode do you select and what wire feed setting,
volts and weld travel speed would you set?
Wire feed___ Amps.____ Volts____ Weld Travel____ ipm
You believe you can use the start point of spray transfer on your 1/8 - 3/16 (3 - 5 mm) steel and stainless parts. With that 0.045 (1.2mm) wire, where would you set the wire feed and the voltage and what will be the weld deposition rate?
Answer.Wire feed ___Volts__Deposition__lb/hr
Which of the following is considered an optimum short circuit "weld
voltage range" for either an 035 or 045 (1 - 1.2 mm) wire?
18 volts [b]17 - 24 volts [c]13 - 18 volts [d]16 - 20 volts.
Why avoid the back hand technique when welding thin gauge < 2 mm?
What is the best "weld position" to an 18 gage, one meter steel box?
Which of the following is the manual welded recommended "thickness
using an 0.035 (1mm) wire and the short circuit transfer?
26 gauge to 16 gauge, [b] 18 gauge to 12 gauge, [c] 14 gauge to 8 gauge.
Provide robot or mechanized weld data for the following 1/8 (3 mm) steel parts. The parts are welded vertical down.
The parts have a 0.060 weld gap. Conventional CV. MIG power source. Wire 0.035.
(1mm). Gas Ar 75% - CO2 25%;
wire feed setting.
[c] weld travel rate,
Wire Feed Rate____ Volts____ Weld Travel Rate_____.
Why does a robot allow you to MIG weld thinner gage than a manual welder can weld?
What minimum robot steel thickness
can you manual weld with an 0.035 wire and the spray transfer mode?
of these MIG gases provides dissociation in the arc?
argon, helium, hydrogen, carbon dioxide.
[a] What is MIG gas dissociation and how does it benefit a MIG weld?
Your 1/8 (3.2mm) stainless application can be welded using a low spray transfer setting with that E316. 0.035 (0.9mm) wire. Provide the wire feed rate and weld voltage and as you have to figure out how much weld wire is required, provide the weld deposition.
WF_____ inch/min. Volts____Deposition___lb/hr
You are ready to weld a
3/16 (5mm) fillet weld. Using spray transfer and an 0.045 (1.2mm) carbon steel
wire, select the wire feed rate, voltage, weld deposition.
WF ___inch/min. Volts__ Deposition__ lb/hr.
 Using argon 10 - 20% with an 0.045 (1.2mm) E70S-6 wire, provide an optimum, manual 1/4 (6 mm)
fillet weld with the spray
transfer mode. Provide the wire feed setting, voltage and
Answer. Wire feed __inch/min. Voltage___ Deposition Rate___ lb/hr.
What robot or mechanized wire feed rate, voltage, weld travel rate, position and welding gas
would you use to weld a 0.035 (1 mm) steel galvanealed, gage application with
an 0.035 MIG wire?
Wire Feed___ Voltage___ Weld Travel Rate___ Part Position.
Without changing the wire feed setting you increase the robot or mechanized weld
Which of the following would you typically have to adjust to compensate.
increase weld volts,  decrease weld volts.
Answer. _____Explain why _________
When robot welding you have to
change the contact tip more than once a day due to the wire burn backs at the weld
start. For the weld and start data you are using an 0.045 (1.2mm) wire set at
420 ipm with 30 weld volts. What changes would you make to the weld start data
to eliminate wire burn backs?
Why will this data work?_________________
You are robot welding with an
0.045 wire and 80 argon 20 CO2 gas. The weld and end data wire feed is 320 inch/min
with 24 volts. There is a large drop on the end of the wire at the weld ends and weld start issues are frequent, explain why.
Manual welding. Which of these gas mixes will provide the most weld fusion and lowest weld porosity
when MIG welding with an 0.045 wire in the spray mode and why?
argon - 2 oxy  argon - 5 oxy  argon - 10 CO2
 argon - 8 Co2 - 2 oxy
 argon - 20 CO2.
With manual your weld, you note the weld transfer is globular producing excess spatter. The weld wire is 0.035 (1 mm) and gas is 80% argon - 20% CO2. The carbon steel parts welded are 3 - 4 mm.
The weld data is 180 amps at 24 volts, what adjustments to the weld parameters
do you make to reduce the globular transfer and explain why?
You are welding with a mechanized carriage and you need to establish a multi-pass,
MIG weld procedure for a 60 degree vee groove flat position weld on 25 mm steel
parts. With the 0.045 (1.2mm) wire and 10 - 20% CO2 gas provide the wire feed rate, voltage, travel
rate, and deposition rate for an optimum fill pass.
inch/min. Volts____ Travel Rate___ Deposition___
You have to weld thin gauge (0.040 - 0.080), 300 series stainless with an 0.035, (1 mm)
309 MIG wire, and you the gas salesman recommended the common three part
helium tri mix, 90 He / 7.5 Ar / 2.5 CO2.
Why is this global tri gas mix the wrong gas choice, and what is the optimum
gas mix and why?,
(hint Ed developed the gas mix you should be using its in the MIG gas section at www.weldreality.com)
Answer. The tri mix
is a poor choice because.__________________
The correct gas choice for the thin stainless is____________________
 You are manually MIG welding using pulsed or spray transfer on an aluminum application.
The aluminum parts are clean, however extensive black soot occurs either side
of the weld. What simple weld parameter adjustment will instantly decrease the
black soot and why does this weld parameter adjustment work?
weld parameter adjustment is_______
This parameter adjustment works because,_______
You are manually pulsed MIG welding a steel part. The part thickness and
weld needs an average weld current of 240 amps. Provide the pulsed peak current
and back ground current to attain 240 amps?
With that robot or manual weld, what should be the maximum fillet weld size for
a horizontal fillet size_______ Why_____?
a flat fillet size______. Why_____?
What is the minimum weld voltage when robot welding with spray transfer, using
either an 0.035 or 0.045 wire (1 - 1.2 mm) and argon 20% CO2?
[a] 22 volts
[b] 23 volts [c] 25 volts [d] 27 volts [e] 29 volts
Using an 0.052, (1.4 mm) steel MIG wire, what is the minimum part thickness
you can manually spray weld without weld burn through issues.
is the minimum weld current required for spray with this 0.052 wire?
With an 0.045 (1.2 mm) wire and argon 20% CO2 gas, you are welding a 10 gauge
carbon steel part to a 3/16 (5 mm) part, The weld current is 240 amps with 24
volts. The parts are covered with spatter and the tips need changing every hour.
pulsed steel or stainless MIG weld is too narrow and convex,
which pulsed parameter
do you change to make the weld wider?
[a] Why will this change give the
Your pulsed steel or stainless MIG weld is erratic, the arc length is too
short and there is no more
adjustment from the arc trim. Which of the following
pulsed parameters would you adjust and why?
Answer. Peak, Back Ground,
Wire Feed, Weld Amps, Frequency.
Your manual pulsed steel or stainless MIG weld droplets are too large.
Which of the following pulsed parameters would you adjust and why?
Peak. Back Ground. Wire Feed. Weld Amps. Pulsed frequency.
 You rotate your steel pipe and want to provide an optimum short circuit open root. provide the wire feed, volts and travel rate.
you are looking to attain process optimization through teaching your self, or
providing weld process control training for others, the following resources are
all you need.
The Book: "
A Management & Engineers Guide To MIG
Quality, Productivity & Costs"
2. A unique robot
MIG process control training or self teaching resource.
Robot MIG Welds from Weld Best Practices - Weld Process Controls".
unique manual MIG training resource.
Manual MIG Weld Process Optimization from Weld Best Practices - Weld
A unique Flux Cored process training or self teaching Resource.
"The Requirements for Optimum Manual and Automated Flux Cored Plate and Pipe welds.
de Soldadura MIG Manual"
(Same as item 6 in Spanish)
Self Teaching MIG Process Control Book / Video.
Made Simple in English).