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* Machine strikes an arc between the work and a consumable wire electrode, melting a pool of metal
** Welding isn't like soldering, welding melts the pieces of metal and allows them to flow together and mix with the filler material. When it re-solidifies it's one continuous piece of metal
* Wire dips in and out, adding metal to the pool
* Gas shields the hot metal from the air
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* Arc-eye hazard to you and people around you
** Using an auto-darkening welding mask
** Checking masks with a strong light source
** Suitable settings on mask (9-11, 12 maybe - start at 10 and adjust)
** Shouting "Eyes" if there are other people around
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** The voltage is low, but you still don't want to touch it
** Mind what you point the torch at
** Power on this welder cuts off as soon as the trigger is released, which is not the case for all welders.
** NO RINGS, NO WATCHES!!
** Users with implanted medical devices should seek doctor's approval before welding, it's not usually a problem, but please do check
** The welder plugs into aone of the 16A round socketsockets on the central pillars downstairs
*** there is a 16A socket on the pillar, it shares power with the bandsaw.
*** If the bandsaw is used at the same time it may trip the breaker
*** Use only suitably rated industrial extension leads, they're in the desk drawer B1B
*** Extension leads are a trip hazard, warn people
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* Clean up weld area - be aware of burning paint
* Clean area for earth clamp
* BevelingBevelling edges to form a path for the bead on butt joints
** No bevel on thin materials
** Regular 2/3rds bevel most of the time
** BevelingBevelling from both sides for very thick
** Multipass and double sided welding are options
|| Proper preparation is necessary for good welds, cover bevel patterns for other weld types later
|-
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** Resting your other hand on something to use as a guide
* How the pool forms (Only cover dip transfer)
* The pool wants to move, you need to just keep pace with it
* Taking the pool "for a walk"
* Keeping the wire aimed at the nose of the pool
** Further towards the tip of the pool = fast move, thinner bead, less penetration
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* Arc won't strike - Ground clamp not connected
* Weld moves around erratically - too much gas or influence from holding magnets
|| RecognizingRecognising faults and knowing how to fix them
|-
| PracticingPractising a steady bead || Inductee practices laying down a straight and steady, well-fused bead on flat stock till competent || Getting the basics right
|-
| Butt joints ||
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** Flap discs will tidy up welds that are good to start with
** Grinding discs will remove messy welds quickly
* Shutting off the gas before un-hooking the couplings
* WhenWant you'refor donewelder fans to stop then shut off the power to the welder and putting the leads away
* Sweeping up and putting everything back where it belongs
* Working out your total weld length and paying for it
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| Final thoughts ||
* This has only been an extremely brief over-view of MIG welding
* Do not expect your joints to be structurally sound or pretty until you have practicedpractised
* The sMIG feature is providing you a LOT of help on this welder, if you switch to a welder without sMIG you may find things a lot harder
* If you want to weld aluminium or magnesium alloys, Stainless Steel, Brazing or other techniques then you can look at [[Tools/TIG/induction#level2|TIG level 2]] or [[tools/mig/induction#level2|MIG level-2]] inductions although it's not compulsory to do level-2 inductions if you've already done the relevant level-1 inductions and if you think you can manage these techniques without further help
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|| Closing comments
|}
<div id="update"></div>
 
== Update session for conversion from Clarke 150A unit to ESAB EMP235ic ==
rLab has recently acquired an ESAB Rebel EMP235ic MIG welder which is considerably more capable than the old Clarke 150A unit but it's controls and operation are a little different so people who've completed induction on the Clarke unit are required to have an update session to be inducted on the EMP235ic. This update session is anticipated to take around 20 minutes.
 
{| class="wikitable"
|-
! Topic !! Detailed contents
|-
| Safety || Very much similar to the Clarke unit but be aware this machine can output a higher voltage if mis-set. Also as the EMP235ic can output considerably higher currents, darker shades on masks may be called for. This is a 16A unit and should be connected to a 16A or 32A power supply using industrial type extension leads. When using the bandsaw connection point then be aware of the risk of tripping if the bandsaw is in use at the time.
|-
| Controls || The controls on the EMP235ic are very different, it is controlled via an LCD screen and a menu system. For the level 1 you should only be using the machine in Smart-MIG (sMIG) mode. In this mode you need only tell the welder what size wire you are using and how thick the material to be welded is. You may optionally also set a weld profile but unless you're sure of your needs, leave it on neutral. Gas flow should remain at 8L/min for normal welding operations, optionally increasing to 12L/min for plate above 5mm thick. On very thick materials then you need to be aware that the torch is only rated to 150A so you may need to run quite short duty cycles.
|-
| Welding || Position, travel direction, and spacing should all be the same, but be aware that the welder often starts out a little rough for the first 1-2 seconds as the sMIG feature learns what you're doing an corrects so if the weld sounds odd when you pull the trigger, DO NOT STOP, give sMIG time to correct before you decide there's a problem. Be aware that although this welder is capable of globular and spray transfer welding mode when in manual settings, globular and spray transfer should be impossible to initiate while in sMIG mode. Weave patterns should be executed more slowly than usual to avoid confusing the learning feature.
|-
| Welding problems || In previous inductions a range of problems were demonstrated for you to learn to recognise. With this new welder in sMIG mode many of those problems are now impossible. You no longer need to consider wire feed rate issues or power issues as those are chosen automatically. Travel speed and torch position still need to be considered as sMIG cannot completely correct those for you although it will give you considerably more margin for error and still get a good weld.
|}
 
 
 
<div id="level2"></div>
 
== MIG Welder induction - Level 2 ==
Level 2 induction should cover more advanced uses,. thereNormal willmachine beusage acharges chargeapply ofduring £25 for level-2this induction, toyou covershould theexpect increasedit to cost ofaround sourcing£10-15 materialsplus andmore trainerfor timepractice associatedafterwards withif theseyou morewant complexto issues.(Strongly recommended)
 
=== Main level 2 induction ===
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** But if your welds are structural or otherwise sensitive to contamination, don't use it
* Controlling weld distortion
** Metal pulls towards the heat source when it cools and so it pulls towards the weld and in the direction of travel
** You CANNOT prevent distortion, but you can control it.
** Extensive tacking and clamping will help reduce it a bit.
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