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MAG Welding Defined

 

MAG WeldingRobotic welding is an automated process that increases efficiency, consistency, and your ROI.   Used MAG welding robots are the perfect contender for welding processes where the quality and speed of the repetitive weld are crucial.  

Metal Active Gas (MAG) automated Welding is similar to MIG welding, yet differs in the type of shielding gas used. They are both sub types of welding method classified as GMAS (gas metal arc welding). However, MIG uses Metal Inert Gas while MAG uses Metal Active Gas. 

The heat for the welding process is created by a DC electric arc that helps to fuse the consumable metal electrode to the piece that is being worked on. This metal electrode (a small diameter wire) is fed by powered feed rolls (wire feeder) and becomes part of the weld pool. Both the arc and the weld pool are shielded by a chemically active gas. An active gas is in the protective gas category of M21, also known as mixed gas 18 or MIX 18. These gases meant to shield, also react during welding and can affect the seam surface, metallurgy, penetration, behavior, arc stability, and droplet transition. This gas is discharged to help prevent the molten metal beneath the arc from oxidizing.

Take a look at this diagram below, that represents a MAG weld area, to better understand the MAG process. 

MAG Weldingphoto courtesy of wikipedia.com

(1) Direction of travel, (2) Contact tube, (3) Electrode, (4) Shielding gas, (5) Molten weld metal, (6) Solidified weld metal, (7) Work piece

If necessary, the compositions of gas can be mixed up and changed for the welding process to actively affect and adapt to the right material. Typically, MAG is used for steel and MIG for nonferrous metals.

There are three metal transfer modes that can be used, depending on the operating features necessary, for the process. Short-circuiting and pulsed metal transfer are perfect for low current operations. Short-circuiting (“dip transfer”) has the molten metal form on the tip of a wire and is transferred by the wire dipping into the weld pool.  Spray transfer is used during high welding currents.  This technique must use higher voltage to make sure the wire doesn’t make contact with the weld pool. The molten metal on the tip of the wire transfers to the weld pool in the form of a spray of small droplets (smaller than the diameter of the wire). These droplets are then detached randomly across the arc by applying pulses of currents.  The pulsed mode was developed as a means of stabilize the open arc below the threshold, to avoid spattering and short-circuiting.

After better understanding the MAG process, it is easy to see the advantages to automating a factory with welding robotics, especially used ones! IThe biggest advantage to buying used robots is savings. If you buy a used robot, you will pay less (up to 50% less!) and receive a hard-working, reliable system with the potential to last as long as a new robot. All of our robots go through our reconditioning process that begins with a comprehensive reconditioning and inspection report, ensuring you only the best! 

Overall, robotic welding automation includes faster, consistent cycle times, no break in production, and overall better weld quality.  Used robotic weld cells are more productive because they can work without breaks or days off. Additionally, an automated welder is more consistent and thorough and can move from one weld to the next quickly, speeding up the entire process.

Interested in automating a MAG operation, now?  RobotWorx is here to help. Our highly-trained staff can assist you in deciding which robot is best for your application needs. They can also help you design and fabricate your MAG  system. For more information, contact RobotWorx at 740-251-4312 or contact us here.