Lincoln Electric IM822 manual Gmaw MIG Welding ARC, Process Selection

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B-7

OPERATION

B-7

The “arc stream” is seen in the middle of the picture. This is the electric arc created by the electric current flowing through the space between the end of the wire electrode and the base metal. The temperature of this arc is about 6000°F, which is more than enough to melt metal. The arc is very bright, as well as hot, and cannot be looked at with the naked eye without risking painful injury. The very dark lens, specifically designed for arc welding must be used with the hand or face shield whenever viewing the arc.

The arc melts the base metal and actually digs into it much as water through a nozzle on a garden hose digs into the earth. The molten metal forms a molten pool or crater and tends to flow away from the arc. As it moves away from the arc, it cools and solidifies.

The function of the Innershield cored wire electrode is much more than simply to carry current to the arc. The wire core is composed of fluxes and/or alloying ingre- dients around which a steel sheath has been formed. It is simply a stick electrode turned inside out in a con- tinuous wire form.

The cored wire melts in the arc and tiny droplets of molten metal shoot across the arc into the molten pool. The wire sheath provides additional filler metal for the joint to fill the groove or gap between the two pieces of base metal.

The core materials also melt or burn in the arc and perform several functions. They make the arc stead- ier, provide a shield of smoke-like gas around the arc to keep oxygen and nitrogen in the air away from the molten metal, and provide a flux for the molten pool. The flux picks up impurities and forms the protective slag on top of the weld during cooling.

After running a weld bead, the slag may be removed with a chipping hammer and wire brush. This improves appearance and allows for inspection of the finished weld.

Since machine size and output characteristics limit the size and type of wire electrode which can be used, Lincoln 0.035’ (0.9 mm) NR-211-MP Innershield elec- trode is recommended for Self-Shielded Flux Cored Arc Welding.

THE GMAW (MIG) WELDING ARC

Figure B.8 illustrates the GMAW (MIG) welding arc. Solid wire does not contain fluxes or ingredients to form its own shielding and no slag forms to protect the molten weld metal. For this reason, a continuous even flow of shielding gas is needed to protect the molten weld metal from atmospheric contaminant’s such as oxygen and nitrogen. Shielding gas is supplied through the gun and cable assembly, through the gas nozzle and into the welding zone.

 

 

Gas nozzle

Solid wire

Shielding gas

electrode

 

 

 

 

 

 

 

 

 

Weld metal

Base metal

 

 

 

 

FIGURE B.8

When comparing the GMAW and FCAW processes, you can see that the principal difference between the two lies in the type of shielding used. GMAW uses gas for shielding, thus we have Gas Metal Arc Welding. FCAW uses the melting or burning of the core ingredi- ents for shielding, and is thus termed Self-Shielded Flux Cored Arc Welding.

The recommended wire for Gas Metal Arc Welding (MIG) is Lincolnweld 0.025” (0.6 mm) L-56 electrode. Lincolnweld” L-56 is capable of welding a wide range of mild steels in all positions, however, more skill IS required for out-of-position welding with the GMAW process.

PROCESS SELECTION

By gaining knowledge of the differences between the two processes, you will be able to select the best process for the job you have at hand. In selecting a process, you should consider:

MIG PAK HD

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Contents MIG PAK HD Safety California Proposition 65 WarningsElectric Shock can kill Welding Sparks can cause fire or explosion IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcThank You Master Table of Contents for ALL Sections Installation Technical Specifications MIG PAK HDMIG PAK HD Safety Precautions Identify and Locate ComponentsElectric Shock can kill Changing Polarity Select Suitable LocationStacking Input ConnectionsRequirements for Maximum Output Shielding GAS ConnectionCode Requirements for ELECTRI- CAL Input Connections Extension Cord UsageOperation Operational Features and ControlsDesign Features and Advantages General DescriptionLimitations Controls and SettingsWelding Capability Welding OperationsContact TIP Wire Electrical Electrode Stickout 3OPERATIONB-3Shielding GAS Making a Weld Table B.1 MIG PAK HDOverload Protection Cleaning TIP and GAS NozzleChanging Machine Over to Feed Other Wire Sizes Thermal ProtectionLearning to Weld ARC-WELDING CircuitSELF-SHIELDED Fcaw Flux Core Welding ARC Gmaw MIG Welding ARC Process SelectionFor Gmaw MIG Process Common MetalsJoint Types and Positions For Fcaw Innershield ProcessPenetration Fillet WeldsVertical-down Welding Machine SET UP for the SELF-SHIELDED Fcaw ProcessWelding Techniques for the SELF- Shielded Fcaw Process Correct Welding PositionCorrect Electrical Stickout ESO Correct Welding SpeedBack-Stepping Mild SteelElectrode Machine SET UP for the Gmaw MIG Process Welding Techniques for the Gmaw MIG ProcessMild Steel Electrode GAS TypeTroubleshooting Welds Operation Innershield Welding Wire AccessoriesAccessories MIG Welding WireItems Requiring No Maintenance MaintenanceMaintenance Safety Precautions Routine and Periodic MaintenanceComponent Replacement Procedures Cleaning the GUN LinerCleaning Components AS Required Changing the Contact TIPGUN Assembly Removal Work Cable InstallationTroubleshooting HOW to USE Troubleshooting GuideProblems Possible Areas Symptoms Misadjustments Recommended Course of ActionAuthorized Field Service Facility Contact your local LincolnWelding Problems Diagrams WiringdiagramPrecaucion Warnung

IM822 specifications

The Lincoln Electric IM822 is a cutting-edge multi-process welding machine that is making waves in the welding industry for its advanced capabilities and user-friendly features. Known for its versatility, the IM822 supports a variety of welding processes including MIG, TIG, and stick, accommodating a wide range of applications in both industrial and commercial settings.

One of the standout features of the IM822 is its inverter technology, which enhances both performance and efficiency. This inverter-based system allows the welder to output a stable arc, even in fluctuating input power conditions, making it ideal for use on job sites with inconsistent power supplies. The lightweight and compact design of the IM822 are direct benefits of this inverter technology, allowing for portability without sacrificing power.

The IM822 also boasts an impressive duty cycle, which allows for prolonged use without overheating. This characteristic is crucial for professional welders who require consistent, high-quality welds over extended periods. Additionally, it is equipped with an easy-to-read digital display that presents key information such as voltage and amperage settings, giving operators precise control over their work.

User-friendly interface is another hallmark of the Lincoln Electric IM822. The machine comes with intuitive controls that make it easier for both novice and experienced welders to navigate through settings quickly. With preset programs, users can select the most suitable parameters for specific materials and thicknesses, thereby enhancing productivity and reducing setup time.

Moreover, the IM822 excels in providing versatile welding capabilities, allowing it to handle various materials, including stainless steel, aluminum, and mild steel. The machine's robust construction further ensures durability, making it a reliable tool that withstands the rigors of demanding work environments.

Incorporating safety features such as thermal overload protection and an automatic shut-off system, the IM822 promotes safe operation, minimizing the risk of accidents. With a history of quality and innovation backing it, Lincoln Electric has positioned the IM822 as a go-to choice for welders seeking a modern solution that doesn't compromise on power or usability.

In conclusion, the Lincoln Electric IM822 combines advanced inverter technology, user-friendly operation, and robust welding capabilities, making it an excellent investment for professionals in the welding field. Whether for fabrication, repair, or maintenance applications, the IM822 stands out as a versatile and dependable welding solution.
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