2398. Pressurized Air-Cooled Metal Inert Gas Welding Technology

Paper

Abstract

Little innovation has occurred relating to heat deposition in the MIG welding industry since the process was first introduced in the 1940s. The MIG welding process is often referred to as ”semi-automated welding” because it uses a continuous supply of spooled metal wire for the weld puddle, as opposed to twelve inch long metal filler rods. Interchangeable MIG gun assemblies are used with wire feed and power sources supplied by various equipment manufactures. Gun assemblies are cooled either by ambient air, or, in high-duty cycle applications, by water-cooled MIG guns with water supplied by water circulators. MIG welding is suited for many industrial applications that require the permanent bonding of similar metals. Some high-duty cycle welding is performed by robot and automatic arc welding systems. The automated processes are becoming the popular way to cut costs and speed up production with most manufactures. The PAC*MIG gun was designed to compete with water-cooled MIG guns sold by most of the MIG welding accessory manufacturing businesses (‘PAC’ stands for PRESSURIZED AIR-COOLED and ‘MIG’ stands for METAL INERT GAS. This is a trademark of PAC*MIG, Inc.). Water-cooled MIG guns are used for intensive arc welding applications that require high welding wire deposition, high amperages and high heat dissipation. A water-cooled MIG welding environment is inherently problematic. Typical problems surface within six months of initial installation and include water leaks, limited water circulation, corrosion of copper parts and constriction in the gun and water circulator.