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  |Has imagedesc=The Millermatic 210

  |Has imagedesc=The Millermatic 210

  |Has description=

  |Has description=

  |Has certification=

  |Has certification=https://georgefox.instructure.com/courses/1267

  |Has make=Miller Electric

  |Has make=Miller Electric

  |Has model=Millermatic 210

  |Has model=Millermatic 210

  |Has ace=Jack Ellis;jellis18@georgefox.edu

  |Has ace=Wyatt Bertis;wbertis22@georgefox.edu

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}}

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==Description==

==Description==

====Terminology====

====Terminology====

* MIG Welding - Metal inert gas is a welding process in which an electric arc forms between a consumable MIG wire electrode and the base metal, which heats the base metal, causing them to melt and join. Along with the wire electrode, a shielding gas feeds through the welding  gun, which shields the process from contaminants in the air.

 

* Gun - The piece that is held while welding and feeds the weld metal into the base metal.

*MIG Welding - Metal inert gas is a welding process in which an electric arc forms between a consumable MIG wire electrode and the base metal, which heats the base metal, causing them to melt and join. Along with the wire electrode, a shielding gas feeds through the welding  gun, which shields the process from contaminants in the air.

* Base Metal - The metal pieces that are being joined together.  

*Gun - The piece that is held while welding and feeds the weld metal into the base metal.

* Filler Metal - The material added to the weld from the weld spool.

*Base Metal - The metal pieces that are being joined together.

* Coupons - Small pieces of metal used to practice welding.

*Filler Metal - The material added to the weld from the weld spool.

* Contact Tip - The metal tube connected to the gun that guides the wire and transfers the current to the filler metal.

*Coupons - Small pieces of metal used to practice welding.

'''[https://www.millerwelds.com/files/owners-manuals/o1325a_mil.pdf User Manual]'''

*Contact Tip - The metal tube connected to the gun that guides the wire and transfers the current to the filler metal.

 

[[Media:O1325a mil.pdf|MIG Welder User Manual]]

==Training==

==Training==

====Overview====

 

====Operation====

MIG welding may be the simplest welding method to learn, but that does not mean it is easy. First, it is important to wear the correct safety gear, i.e. closed shoes, pants, a welding coat, a welding helmet, and welding gloves, otherwise you will be burned by the UV light emitted by the welding arc (think of a really bad sunburn). You must also make sure the machine is set up properly. To do this, the gas cylinder valve should be opened all the way and the regulator adjusted to roughly 15 CFH. Depending on the material you are welding the voltage and wire feed speed will vary. You can find a settings chart located inside the cover of the welder. Secure your work pieces using clamps and magnets to hold them in position. Make sure to clamp the ground clamp to the work piece or the metal table near the welding position. If you clamp the ground to the table make sure the work piece has good contact with the table near the ground clamp. The most difficult piece is keeping the correct  gun angle, keeping a consistent travel speed/pattern, and maintaining the correct distance from the work piece. If you have spent time on the welding simulator then the  gun angle and travel speed/pattern should be simple to replicate. It is more difficult to visually reach the correct distance from the material but if the welder is making a nice sizzling (just like frying bacon) sound then it should be correct. If there is a lot of popping the the gun is too far away and if there is more of a bubbling sound then it is too close. When you have completed the welding process reset the space by putting away any scrap metal and putting everything back.

MIG welding may be the simplest welding method to learn, but that does not mean it is easy. First, it is important to wear the correct safety gear, i.e. closed shoes, pants, a welding coat, a welding helmet, and welding gloves, otherwise you will be burned by the UV light emitted by the welding arc (think of a really bad sunburn). You must also make sure the machine is set up properly. To do this, the gas cylinder valve should be opened all the way and the regulator adjusted to roughly 15 CFH. Depending on the material you are welding the voltage and wire feed speed will vary. You can find a settings chart located inside the cover of the welder. Secure your work pieces using clamps and magnets to hold them in position. Make sure to clamp the ground clamp to the work piece or the metal table near the welding position. If you clamp the ground to the table make sure the work piece has good contact with the table near the ground clamp. The most difficult piece is keeping the correct  gun angle, keeping a consistent travel speed/pattern, and maintaining the correct distance from the work piece. If you have spent time on the welding simulator then the  gun angle and travel speed/pattern should be simple to replicate. It is more difficult to visually reach the correct distance from the material but if the welder is making a nice sizzling (just like frying bacon) sound then it should be correct. If there is a lot of popping the the gun is too far away and if there is more of a bubbling sound then it is too close. When you have completed the welding process reset the space by putting away any scrap metal and putting everything back.

====Demonstration====

====Demonstration====

For the first part of the demonstration you will need to show how to setup the welder and perform safe operation. The second part of the demonstration will be performing sample welds on a coupon. You will need to weld several weld lines a weld coupon and choose one of the following joints to weld: lap, butt, or Tee joint. These should be performed on the coupons found in the weld shop. See the image below to see the different types of welds.

For the first part of the demonstration you will need to show how to setup the welder and perform safe operation. The second part of the demonstration will be performing a sample weld on a coupon. To start demonstrate how to weld several 1 inch weld lines a weld coupon and choose one of the following joints to weld: lap, butt, or Tee joint. These should be performed on the coupons found in the weld shop. See the image below to see the different types of welds.

[[File:Weld Types.png|none|thumb|748x748px]]

[[File:Weld Types.png|none|thumb|748x748px]]

====General Procedure====

====General Procedure====

Prior to Welding:

Prior to Welding:

# Place the fume hood over the area you will be welding and make sure it is on. The power switch is located on the wall next to the door and light switch.

 

# Attach the ground clamp to the metal bench your work piece will be on. Ideally, place the ground clamp on the base metal itself to create the smoothest path for the electrical current.

#Place the fume hood over the area you will be welding and make sure it is on. The power switch is located on the wall next to the door and light switch.

# Ensure the work piece is touching the conductive surface of the table. This is critical if the clamp is not touching the base metal.  

#Attach the ground clamp to the metal bench your work piece will be on. Ideally, place the ground clamp on the base metal itself to create the smoothest path for the electrical current.

# Ensure the adjusting screw on the tank regulator is loose (Do not unscrew all the way).

#Ensure the work piece is touching the conductive surface of the table. This is critical if the clamp is not touching the base metal.

# Slowly open cylinder valve all the way. Suddenly opening the valve could cause damage to the regulator.

#Ensure the adjusting screw on the tank regulator is loose (Do not unscrew all the way).

# Slowly turn the adjusting screw (clockwise) to increase pressure to 25 CFH. At first it will spin freely but you will begin to feel resistance as the pressure begins to increase on the leftmost pressure gauge.  

#Slowly open cylinder valve all the way. Suddenly opening the valve could cause damage to the regulator.

# Identify the material type and thickness that you will be welding.

#Slowly turn the regulator screw (clockwise) to increase pressure to 25 CFH. At first it will spin freely but you will begin to feel resistance as the pressure begins to increase on the leftmost pressure gauge.

# Determine the wire feed rate and voltage to fit your material and wire size. To do this, refer to MIG welding chart for specified adjustments specific to your application. A welding chart is included below for reference and the same chart is mounted inside the cover of the welder. This chart also depends on the wire size which is usually 0.035". [[File:Welder Chart.jpg|none|thumb|706x706px]]

#Identify the material type and thickness that you will be welding.

# Turn on the welder and adjust wire speed and voltage to match the parameters layed out by the welding chart. Refer to the image below to see the controls for doing this. [[File:MIG Controls.png|none|thumb|837x837px]]

#Determine the wire feed rate and voltage to fit your material and wire size. To do this, refer to MIG welding chart for specified adjustments specific to your application. A welding chart is included below for reference and the same chart is mounted inside the cover of the welder. This chart also depends on the wire size which is usually 0.035". [[File:Welder Chart.jpg|none|thumb|706x706px]]

# Ensure you are wearing all necessary protective gear. This should include closed shoes, pants, a welding coat, a welding helmet, and welding gloves. There should be no skin exposed to the welding arc or it will cause burns.

#Turn on the welder and adjust wire speed and voltage to match the parameters layed out by the welding chart. Refer to the image below to see the controls for doing this. [[File:MIG Controls.png|none|thumb|837x837px]]

# Ensure the welding  gun has proper amount of wire protruding from tip (about ¼ inch) and that the  gun nozzle is clean of any debris. You can use pliers to scrape off any debris in the nozzle. If too long, trim excess with the welding pliers. If to short, pull the trigger while the  gun is not in contact with anything and more wire will be fed out.

#Ensure you are wearing all necessary protective gear. This should include closed shoes, pants, a welding coat, a welding helmet, and welding gloves. There should be no skin exposed to the welding arc or it will cause burns.

#Ensure the welding  gun has proper amount of wire protruding from tip (about ¼ inch) and that the  gun nozzle is clean of any debris. You can use pliers to scrape off any debris in the nozzle. If too long, trim excess with the welding pliers. If to short, pull the trigger while the  gun is not in contact with anything and more wire will be fed out.

 

Perform a Weld:  

Perform a Weld:  

# Set up the work pieces in your desired configuration. Magnets and metal clamps are helpful for doing this and can be found on the tray below the tabletop.  

 

# Tack the pieces together in a few places by holding the  gun at the proper angle and holding down the trigger for 2-3 seconds. Before pulling the trigger make sure to say "welding" to let everyone in the room know you are about to start. If you do not know the correct angle to hold the  gun go practice some more on the [[Virtual Reality Welding Station]] until you are comfortable with the  gun.  

#Set up the work pieces in your desired configuration. Magnets and metal clamps are helpful for doing this and can be found on the tray below the tabletop.

# Perform as many welds as needed. If you are doing everything right the noise should sound like sizzling bacon. Also, you may need to periodically trim the wire between welds to keep the correct distance from the work piece.  

#Tack the pieces together in a few places by holding the  gun at the proper angle and holding down the trigger for 2-3 seconds. Before pulling the trigger make sure to say "welding" to let everyone in the room know you are about to start. If you do not know the correct angle to hold the  gun go practice some more on the [[Virtual Reality Welding Station]] until you are comfortable with the  gun.

#Perform as many welds as needed. If you are doing everything right the noise should sound like sizzling bacon. Also, you may need to periodically trim the wire between welds to keep the correct distance from the work piece.

 

After Welding

After Welding

* Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live.

#Bleed any remaining gas by depressing trigger until regulator drops to 0. Make sure the gun is not in contact with anything while doing this.

* Don’t weld lead, zinc, copper, cadmium, or beryllium or any coated metals. Welding these materials can be harmful if not equipped with proper safety gear and training.  

#Back out adjusting screw on regulator (Do Not unscrew all the way).

* Don’t weld in wet gear or standing water because this could create a new path for the electrical current to travel and cause a severe electrical shock.

#Turn off the welder.

* Always turn gas and the welder off when you are done in the welding shop to ensure there are no leaks that could cause asphyxiation (suffocating from lack of oxygen).  

#Carefully coil the gun and return it to the welder. Make sure it does not get kinked.

* Never weld without a welding helmet. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Be aware that sparks fly off from the weld.

#Remove the ground clamp and clean up any scraps and slag from the work area.

* Never weld without gloves. Gloves protect your hands from the heat as well as the arc rays. No bare skin should be exposed.

* Don't weld with the vent hood off. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. Asphyxiation can also occur due to the confined nature of the welding shop and the use of welding gasses.

* Always weld with the door open to lower the risk of asphyxiation.

* Don't weld with the gas off. This can damage the machine.

* Please avoid touching the hot metal surrounding the weld, even if you are wearing welding gloves. You could get burned and the heat may damage the gloves.

* Never weld alone.

==Certification==

==Certification==

[https://foxtale.georgefox.edu/moodle/course/view.php?id=31362 Foxtale Course]

[https://georgefox.instructure.com/courses/1267 Canvas Quiz]

==Troubleshooting==

==Troubleshooting==

* Wire feeds from the  gun but welding doesn't occur - Check that the ground clamp has solid contact with the work piece and that there is solid contact with the table if the clamp is on the table.  

 

* The welding process is burning through the work piece - Double check the welding parameters chart to ensure the wire speed and voltage are correct.  

*Wire feeds from the  gun but welding doesn't occur - Check that the ground clamp has solid contact with the work piece and that there is solid contact with the table if the clamp is on the table.

* Trouble starting the weld at the correct distance - Trim the wire to around 1/4" so that the gun can be closer to the work piece.  

*The welding process is burning through the work piece - Double check the welding parameters chart to ensure the wire speed and voltage are correct.

* Wire feeding at an erratic rate - Contact the supervisor or tech if you experience this issue.

*Trouble starting the weld at the correct distance - Trim the wire to around 1/4" so that the gun can be closer to the work piece.

*Inconsistent arc - Check that your workpiece is clean of thick mill scale. The contact tip may also need replacing, contact supervisor or tech.

*Wire feeding at an erratic rate - Contact the supervisor or tech if you experience this issue.

==Maintenance==

==Maintenance==

|Clean slag from the gun nozzle

|Clean slag from the gun nozzle

|As needed

|As needed

|Student  

|Student

|N/A

|N/A

|-

|-

|Inspect/Repair cracked weld cables

|Inspect/Repair cracked weld cables

|Every 3 months

|Every 3 months

|Ace  

|Ace

|

|

|-

|-

|Clean and tighten weld terminals

|Clean and tighten weld terminals

|Every 3 months

|Every 3 months

|Ace  

|Ace

|

|

|-

|-

|Blow out or vacuum inside of welder  

|Blow out or vacuum inside of welder

|Every 6 months  

|Every 6 months

|Ace

|Ace

|

|

|-

|-

|Remove drive roll and carrier and lubricate

|Remove drive roll and carrier and lubricate

|Every 6 months  

|Every 6 months

|Ace  

|Ace

|

|

|-

|-

|Replace contact tip

|Replace contact tip

|As needed

|As needed

|Ace  

|Ace

|

|

|}

|}