Butt Welding of Unalloyed and Alloyed Steels
Load-bearing weld joints with high deposition rate and reproducible seam quality – from thin sheet to thick-walled, manually or automated.
MIG/MAG welding, also known as metal shielding gas welding (GMAW – Gas Metal Arc Welding), is one of the most important arc welding processes in modern manufacturing and maintenance. A continuously fed wire simultaneously serves as arc carrier and filler material; externally supplied shielding gas protects the arc and weld pool from atmospheric influences.
Characteristic features are high deposition rates, reproducible welding results and excellent automation capability – from manual workshop applications to robotic cells in series production. Typical fields of application include mechanical and plant engineering, steel and automotive construction, conveying technology, and repair and regeneration processes.
Through the choice of wire and shielding gas, MIG/MAG welding processes can be fine-tuned: from short-arc thin-sheet welding to high-performance spray arc with deep penetration. This gives the process an exceptionally wide application range – including both joining and hardfacing.
MIG/MAG Welding for Joining, Hardfacing and Automated Manufacturing
We deploy MIG/MAG welding specifically when components need to be joined, repaired or provided with functional protective coatings productively, reproducibly and with high quality. The process is suitable for unalloyed, low-alloyed and high-strength steels as well as aluminium, copper and stainless steels – manually, semi- or fully automated. Depending on requirements, MIG or MAG shielding gases, solid or flux-cored wires and open-arc technologies are used.
MIG Welding of Aluminium, Copper and Stainless Steels
Clean, low-oxidation weld seams on non-ferrous metals with inert gases such as argon or argon-helium mixtures – ideal for aluminium structures and stainless steel applications.
MAG Welding in Steel and Automotive Construction
Economical joining welding of unalloyed, low-alloyed and high-strength steels with active shielding gases – the basis for large parts of industrial steelwork.
Hardfacing and Wear Protection with Flux-Cored Wire
Targeted material deposition with gas-shielded or self-shielding flux-cored wires for protection against abrasion, corrosion and thermal loading – also for large layer thicknesses and areas.
Open-Arc Process for Outdoor and Wear Applications
Self-shielding flux-cored wires allow hardfacing without external shielding gas – insensitive to wind and draughts, ideal for construction sites and outdoor use with maximum wear loading.
Contact us with any questions:
We support you in selecting the right welding process and the appropriate solution.
Wear Protection in Practice: MAG Hardfacing on a Screw Conveyor
Screw conveyors in processing and plant technology are permanently subjected to abrasion and friction. Service life and conveying performance decline continuously, leading to unplanned downtime. MAG hardfacing with wear-resistant flux-cored wires deposits durable layers directly on the screw flights – economically, reproducibly and suitable for larger areas. The bond with the base material is created metallurgically and is significantly more durable than thermally sprayed layers.
Screw Conveyor in Bulk Material Operation
Before
Severe material loss on the screw flight due to abrasive bulk materials in continuous operation.
After
MAG hardfacing with wear-resistant flux-cored wire, metallurgically bonded to the base material.
Result
Significantly extended service life, plannable maintenance intervals and reduced procurement costs compared to component replacement.
Advantages of MIG/MAG Welding in Industrial Use
MIG/MAG welding combines high productivity with reproducible weld quality and a range of shielding gases, wires and process variants that covers virtually every industrial application – from thin sheet to hardfacing layer.
The continuous wire feed enables high deposition rates, exactly adjustable process parameters and excellent automation capability in robotic and gantry applications. At the same time, the process allows manual applications with consistent quality in the workshop and on construction sites.
High Deposition Rate and Productivity
The continuous wire feed enables high welding speeds and deposition rates – a key advantage for series production and large weld volumes.
Excellent Automation Capability
MIG/MAG welding can be used both manually and semi- or fully automated – ideal for robotic cells, gantry systems and reproducible series applications.
Reproducible Seam Quality
Stable arc characteristics and exactly adjustable parameters ensure consistent weld quality – a decisive advantage for safety-critical components.
Broad Material and Thickness Coverage
From thin sheet (short arc) to thick-walled steel components (spray arc) – through wire, shielding gas and parameter selection, requirements can be covered flexibly.
Variety of Wires and Shielding Gases
MIG or MAG gases, solid or flux-cored wires, gas-shielded or self-shielding (open arc) – the process offers an exceptionally wide range of solutions.
Economical Hardfacing for Large Areas
High deposition rate makes MAG hardfacing particularly economical for large layer thicknesses and areas, such as on conveyor elements, crushers or mixers.
When Is MIG/MAG Welding the Right Choice?
MIG/MAG welding is the right choice whenever components need to be joined or coated productively, reproducibly and with high quality. Through the choice of shielding gas, wire and arc type, the process can be matched to virtually any material and thickness combination – from thin sheet to thick-walled steel construction.
MIG/MAG particularly demonstrates its strengths in automated steel and automotive construction, in series production, and for larger hardfacing areas. Even in the open-arc process, MIG/MAG remains a first choice where shielding gas supply is difficult and high deposition rates are simultaneously required.
MIG/MAG welding is particularly suitable for applications where:
productive, reproducible weld joints in steel, aluminium, copper or stainless steel components are required.
components are welded semi- or fully automatically in robotic cells or gantry applications.
larger hardfacing areas need to be economically protected against wear, corrosion or heat.
shielding gas supply is difficult – then with self-shielding open-arc flux-cored wires without external gas.
a flexible process with broad material and thickness coverage and high deposition rate is required.
Steelwork in Practice: MAG Welding on a Structural Framework
Structural frameworks in steel and plant engineering must have load-bearing, durable weld joints that safely transfer static and dynamic loads. MAG welding with active shielding gases allows deep penetration, excellent reproducibility and efficient execution of even thick-walled joints. Through spray arc and appropriate wire selection, safety-relevant joints can be produced in a controlled and documented manner.
Structural Joint in Steelwork
Before
Prepared, tack-welded steel components with defined joint preparation and weld edges.
After
MAG welding with active shielding gas mixture, deep penetration and cleanly through-welded seam.
Result
Permanently load-bearing joint, documentable weld quality and productive execution in series.
MIG/MAG Welding Compared to Other Welding Processes
Classification and Characteristics of the GMAW Process
MIG/MAG welding sits between MMA welding, TIG welding and automated laser processes. It combines high productivity with reproducible quality and excellent automation capability. Through shielding gas (inert or active), wire (solid or flux-cored) and arc type (short arc, globular, spray arc, pulsed arc), welding processes can be precisely matched to the application.
Characteristic is the continuous wire feed, which enables high deposition rates and consistent seam quality. This makes MIG/MAG the standard process for series production, steel and automotive construction, plant technology and large-area hardfacing.
Through flux-cored wires and open-arc technologies, the process also covers applications where conventional shielding gas supply is difficult – such as on construction sites or for large-area outdoor wear protection.
Differences to MMA, PTA and Laser Cladding
MMA Hardfacing
MMA hardfacing is more manual and cheaper, ideal for individual repairs and hardfacing without equipment investment. MIG/MAG hardfacing, by contrast, delivers the productivity for large-area deposition work and reproducible layer quality – the standard as soon as quantities or layer areas come into play.
PTA Welding
PTA welding achieves significantly lower dilution with the base material and more precise layer properties, but with higher equipment and process effort. MIG/MAG hardfacing remains the more economical choice when large-area hardfacing layers are required and somewhat higher dilution is acceptable.
Laser Cladding
Laser cladding is the high-end process with minimal dilution and near-net-shape deposition – and correspondingly higher investment and operating costs. MIG/MAG hardfacing delivers durable protective layers at a fraction of the equipment costs, especially for large components and series applications.
Precise Technology. Clear Process. How We Work.
Every hardfacing project follows a structured workflow – from the initial component analysis to the inspected deposit layer. This produces reproducible results tailored to loading conditions, material and operating environment.
1. Component Analysis
In the first step, the geometry, material and operating conditions of the component are recorded. This includes the type of loading – such as wear, corrosion or thermal stress – as well as the required layer properties. On this basis, the appropriate welding process is selected and the process is designed.
2. Selection of Welding Consumable
Depending on requirements, different welding consumables and alloys are used, for example for wear protection, corrosion protection or heat resistance. The material selection is matched to the base material and the subsequent loading to achieve a permanently stable bond.
3. Component Preparation
Before hardfacing, the component is prepared accordingly. This includes cleaning the surface, removing contamination and, if necessary, mechanical preparation of the coating area. A clean surface is the foundation for a metallurgical bond and reproducible layer quality.
4. Hardfacing
Hardfacing is carried out with precisely set process parameters. Energy input, material feed and welding speed are controlled specifically to set layer thickness and penetration behaviour in a controlled manner. This produces homogeneous deposit layers with defined properties.
5. Quality Inspection
After hardfacing, the layer is mechanically post-processed as required, for example by turning or grinding, to achieve the required dimensional accuracy. Finally, the quality inspection of the weld seam and deposit layer is carried out before the component is returned to the customer.
Andreas Frische
Technical Management
Finding the Right Welding Process
Not sure which welding process is right for your application?
We support you in selecting and combining the right processes.
+49 5202 97790-54
Available from 07:45 - 16:30
a.frische@capilla-gmbh.de
Available from 07:45 - 16:30
Without the right welding consumable, there is no stable solution.
In MIG/MAG welding, the wire, shielding gas and their combination determine the properties of the weld joint or coating – from tensile strength and toughness to wear resistance, corrosion and heat resistance.
capilla offers solid and flux-cored wires for MIG, MAG and open-arc applications, matched to material, process and operating conditions – including wear-resistant hardfacing wires with high hard-phase content.
Automated Welding Processes at the capilla LCC
At the Laser Competence Centre (LCC), capilla brings together modern technologies for automated coating and manufacturing. Components are precisely built up, heat-treated and tailored to the application using laser-based processes. Layer thickness, material deposition and process parameters can be precisely controlled – even for complex geometries and series applications.
This produces coating and manufacturing solutions that go beyond conventional welding processes and cannot be realised with traditional approaches in this form.
Frequently Asked Questions about MIG/MAG Welding
MIG/MAG welding, also known as GMAW (Gas Metal Arc Welding), is an arc welding process with a continuously fed wire and external shielding gas supply. The wire simultaneously serves as arc carrier and filler material; the shielding gas protects the arc and weld pool from atmospheric influences.
The term MIG/MAG covers two variants: MIG with inert gases (e.g. argon) for non-ferrous metals and stainless steels, MAG with active gases (e.g. argon/CO₂ mixtures) for unalloyed and low-alloyed steels. International process designations are process 131 (MIG) and 135 (MAG) according to DIN EN ISO 4063.
capilla offers solid and flux-cored wires for MIG, MAG and open-arc applications as well as hardfacing.
In MIG/MAG welding, an arc is struck between a continuously fed wire and the workpiece. The wire melts in the arc and together with the molten base material forms the weld pool. An externally supplied shielding gas surrounds the arc and weld pool, protecting them from oxygen, nitrogen and hydrogen.
Process 131 (MIG) uses inert gases, process 135 (MAG) uses active gases. Through current, voltage, wire feed speed and shielding gas composition, different arc modes can be realised – from short arc for thin sheet to spray arc with deep penetration. Manual, semi-automated and fully automated applications are possible.
capilla supports process design, wire selection and shielding gas configuration for MIG/MAG applications.
The difference between MIG and MAG welding lies exclusively in the type of shielding gas. MIG (Metal Inert Gas welding, process 131) uses inert, non-reacting gases such as argon, helium or argon-helium mixtures. These gases do not react with the weld pool and are particularly suitable for non-ferrous metals such as aluminium, copper, nickel and their alloys.
MAG (Metal Active Gas welding, process 135) uses active shielding gas mixtures, mostly argon-based with CO₂ or oxygen content (e.g. M21 gases). The active gases specifically influence arc behaviour, penetration and metal transfer. MAG is the economically most important process for unalloyed, low-alloyed and high-strength steels.
capilla advises on process selection and supplies appropriate wires for MIG and MAG applications.
MIG/MAG welding is used in virtually all sectors of modern manufacturing and maintenance technology. Typical application areas include mechanical and plant engineering, steel and automotive construction, shipbuilding, conveying technology, apparatus engineering, and repair and regeneration processes. Both joining and hardfacing are possible.
In joining welding, productive, reproducible weld seams are produced for steel, aluminium, copper and stainless steel components. In hardfacing, functional layers are deposited for protection against wear, corrosion or heat – economically even for large layer thicknesses and areas. Open-arc variants allow hardfacing without external shielding gas, ideal for outdoor use.
capilla supplies wires and advisory support for all MIG/MAG application areas.
The central advantages of MIG/MAG welding are high deposition rate, excellent automation capability and reproducible seam quality. The continuous wire feed allows higher welding speeds than MMA welding, while the process remains flexible for manual and semi-automated use.
Through the choice of shielding gas, wire and arc type, MIG/MAG welding can be matched to virtually any material and thickness combination – from thin sheet (short arc) to thick-walled steel components (spray arc). Compared to laser processes, investment and operating costs are significantly lower; compared to TIG welding, productivity is significantly higher.
capilla uses MIG/MAG welding when productive, reproducible and economical welding solutions are required.
With MIG/MAG welding, virtually all common weldable metals can be processed. MAG welding is the first choice for unalloyed and low-alloyed structural steels, high-strength fine-grained steels and heat-resistant steels. MIG welding is used for aluminium and aluminium alloys, copper and copper alloys, nickel-base alloys and corrosion-resistant stainless steels.
The chemical composition of the weld metal is specifically controlled through wire selection. For each material there are appropriate solid and flux-cored wires with defined mechanical and metallurgical properties. Mixed joints between different materials are also possible when wire selection and shielding gas are matched accordingly.
capilla carries wires for steel, stainless steel, aluminium, copper and special alloys as well as hardfacing.
In MIG/MAG welding, different shielding gases are used, matched to material and application. In MIG welding, inert gases are used: pure argon, helium or argon-helium mixtures. They do not react with the weld pool and ensure clean, low-oxidation seams on aluminium, copper, nickel and stainless steels.
In MAG welding, active shielding gas mixtures are used, mostly argon-based with CO₂ or oxygen content (e.g. M21 gases). Pure CO₂ is less common and mostly used in the short-arc range. The active gases influence arc stability, penetration, metal transfer and spatter formation. Mixed gases such as 82% argon/18% CO₂ are standard in steelwork.
capilla advises on the correct shielding gas selection in combination with wire and application.
In MIG/MAG welding, solid or flux-cored wires are used depending on requirements. Solid wires are characterised by clean seam appearance, good arc stability and straightforward processing. They are the first choice for classic joining welding in steel, aluminium and stainless steel applications.
Flux-cored wires consist of a metallic sheath with a powdered filling. They allow higher alloy content, more precise adjustment of weld metal properties and higher deposition rates. In hardfacing, flux-cored wires with carbide or hard-phase content are predominantly used. Self-shielding open-arc wires generate their protection from the powder filling and require no external shielding gas – ideal for construction sites and outdoor use.
capilla supplies solid wires, flux-cored wires and open-arc wires for joining, hardfacing and wear protection.
MIG/MAG hardfacing is used when components need to be protected over large areas or with high layer thicknesses against wear, corrosion or thermal loading. Typical applications are screw conveyors, bucket edges, crusher components, mixer arms and rollers in processing, conveying and recycling technology.
Through flux-cored wires with hard phases, carbides or borides, layers with defined properties can be built up – matched to abrasion, impact, friction, corrosion or heat. In the open-arc process, the shielding gas supply is eliminated, making deposition on construction sites and outdoors economical. The high deposition rate of MIG/MAG is a clear advantage, especially for large areas.
capilla uses MIG/MAG hardfacing for economical, large-area protective layers.
Welding defects in MIG/MAG welding can be avoided by carefully matching wire selection, shielding gas, parameters and component preparation. Common sources of error are unclean weld edges, incorrect wire feed speed, unsuitable voltage, incorrect shielding gas, insufficient gas flow or wind/draught affecting the weld pool.
Preventively: clean weld edges and remove contamination, select wire matched to material, adjust current and voltage to wall thickness and arc type, set shielding gas flow according to torch distance and avoid draughts. In hardfacing, the selection of the appropriate flux-cored wire is critical. Safety-critical components are non-destructively tested (visual inspection, penetrant testing, ultrasound, radiography).
capilla supports wire selection, welding procedure and quality assurance for MIG/MAG welding.