MIG welding is not a one-size-fits-all process. There are so-called “all-around” MIG, sure. Still, there are times when it’s best to use a specific type for specific situations and environments. It is not to mention a specific skill set.
It is not rocket science, but that doesn’t mean you can wing it and hope you get good results. If you want to do it right, you need to use the proper tools and execute the right techniques.
Speaking of proper tools, there are two types we’ll talk about. The Gas MIG Welder (also called “Gas shielded”) and Gasless MIG welder (also called “Self-shielded”).
Yes, MIG without gas is possible. We’ll go through everything you need to know. It is sometimes called no-gas MIG.
Summary
We tested various products and found that the best gasless MIG welder was the Forney Easy Weld 261. YESWELDER produces the best gasless MIG wire. Gasless MIG welders’ main advantage is that they’re easy to use outside. The gasless MIG welders’ main disadvantage is that the result isn’t quite as strong as alternative methods, although they still provide reasonable results.
Here is the summary of our testing:
- Best value: Forney
- Best luxury: YESWELDER
Best gasless welder machines & wire
Are you simply looking for recommendations on the best gasless welders to get you started on your projects? We’ve carefully reviewed the options on the market to bring you the best contender in each category. Here’s our selection of the best gasless MIG wire and tools to try!
Forney Easy Weld 261
The Forney is our top pick, so let’s cover it quickly.
| Name | Easy Weld 261 |
| Brand | Forney |
| Country of Origin | China |
| Feature | Portable |
| Item Dimensions | 16.7 x 12 x 8.1 inches |
| Max amp | 140 |
Pros
- It’s a great starter machine.
- It has several thousand reviews.
- It’s perfect for small repairs.
- It makes less spatter than we thought it would.
Cons
- There are cheaper options out there.
- It’s basic and can only output 140 amp.
- If you’re getting serious about welding, you might want a more serious machine straight away.
Here’s what we’ll look at in the rest of the article:
Table of Contents
Factors to Consider
Have you decided to switch to self-shielded MIG welding? Great! But not too fast. While switching is often a good choice, there are specific considerations you need to think over. There are measures you need to take to ensure that the transition goes smoothly. Here they are.
Compliance to codes
Before you switch, you need to be aware of the structural codes by the D1 committee of the American Welding Society (AWS). More importantly, you need to make sure that you’re complying with those codes.
Furthermore, you need to check if there are additional certifications you need to complete for specific tasks. You must get them requalified with the new procedures in mind if you already have certifications. With that said, it’s ideal that you undergo requalification regularly to ensure that the process is fast and efficient.
Choosing the right equipment
Choosing the right flux core or the best MIG welder is critical when starting this new craft. Self-shielded FCAW requires a constant-voltage power source. You must maintain the recommended voltage throughout the process. If your equipment cannot maintain a steady voltage, mistakes or irregularities (porosity) are expected.
Selecting the correct wire
You need to use the correct wire for self-shielding to work, particularly the self-shielded flux-cored wire. It has different seismic requirements and requires the appropriate strengths. The wire you’re using needs to have the chemical and mechanical properties that can accommodate the structural applications required.
Best practices
While it is easier than most processes, it has attendant challenges that need to be addressed. Here are the key practices that will bolster your success with self-shielded flux-cored welding.
Maintain the right travel speed and angle
When performing work in the vertical position, aim your gun at an angle of 5 to 15 degrees. When working in a flat or horizontal position, make sure that the drag angle is 15 to 40 degrees. Maintain your speed as slowing down can cause the piece to puddle, resulting in slag production.
Maintain correct heat input
You need to maintain proper heat input to ensure that the metals fuse well. To pull this off, use the voltage recommended by the manufacturer relative to the wire diameter. Slag inclusions are likely to occur if you don’t provide enough heat.
Clean the material thoroughly in between passes
By cleaning the surface of the base metal thoroughly between passes, you can remove contaminants that may cause fusion issues. You can remove any slag using a chipping hammer or a wire brush.
Maintain the right penetration
Maintain the right penetration by monitoring how much metal is deposited into the joint within a given time period. You need to ensure enough space between the bead and the joint for the metal. It is especially important when you’re making root passes and maneuvering through wide openings.
The metal will penetrate the base metal and hang from the underside if you go too deep. To prevent excessive penetration, reduce the voltage range to the recommended settings and slow down the wire feeding. If it’s the other way around (lack of penetration), turn up the wire feed speed and increase the voltage range. Set up the joint to make the groove’s bottom more accessible without losing your hold on the wire extension and the arc.
Prevent porosity and worm tracking
Porosity in metal is not pretty to look at, and you’d do well to take the proper measures to minimize it. One good way to prevent porosity is to use filler meals that contain deoxidizers. Also, double-check that the wire stick-out (the wire’s extension length from the gun’s nozzle) is not 1.¼ inch apart from the contact tip.
Another common issue with MIG is the incidence of worm tracks. They are marks made on the bead’s surface due to the fumes released by the wire once the flux has melted off. You can prevent this by maintaining the recommended voltage settings for the wire feed. Maybe you spot signs of worm tracks. The best course of action is to turn down the voltage by increments of 12 volts until the issue is fixed.
Which of these features are important to you?
- Portability
- Setup time
- Cost
- Weld quality
- Outdoor use
- Weld strength
