title = "MIG/GMAW Welding: Setup and Parameters"

content = """
Gas Metal Arc Welding (GMAW), universally known as MIG (Metal Inert Gas) welding, is the primary production welding process at Ridgecrest Metalworks for carbon steel, stainless steel, and aluminum fabrication. Its combination of speed, versatility, and semi-automatic operation makes it the most productive arc welding process for shop fabrication.

In GMAW, a continuous solid wire electrode is fed from a spool through a welding gun by a wire feeder at a preset rate. The arc forms between the wire tip and the base metal; the wire melts and is transferred to the weld pool. An externally supplied shielding gas (from a cylinder) surrounds the arc and molten metal to prevent atmospheric contamination (oxidation, nitrogen porosity).

Shielding gas selection is critical. For carbon steel, 75% argon / 25% CO2 (C25) is the most common mixture—it provides good arc stability, penetration, and low spatter. Pure CO2 gives deeper penetration and lower cost but more spatter. For stainless steel, tri-mix gases (He/Ar/CO2 or Ar/He/CO2) or 98% Ar/2% CO2 are used to minimize oxidation and preserve corrosion resistance. For aluminum, 100% argon is used (CO2 would cause porosity).

Metal transfer modes determine the character of the weld. Short-circuit transfer (low voltage, low wire feed) is used for thin material and out-of-position welding; the wire short-circuits to the puddle repeatedly, feeding metal with each contact. Globular transfer (intermediate parameters) is erratic and spattery—generally avoided. Spray transfer (higher voltage and wire feed speed with Ar-rich gas) projects a fine stream of droplets across the arc without contact—high deposition rate, excellent fusion, but only usable in flat and horizontal positions. Pulse spray transfer uses electronically modulated current to achieve spray-like transfer at lower average heat input, allowing out-of-position use and reduced heat distortion.

Key GMAW setup parameters: wire feed speed (WFS, controls current/amperage), arc voltage, travel speed, stick-out (electrode extension from contact tip to work, typically 5/8–3/4 inch for CO2/mixed gas), gun angle, and shielding gas flow rate (typically 25–35 CFH). Operators must follow the approved Welding Procedure Specification (WPS) for each joint configuration, position, and material.
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version = "0.0.1"
