1. MIG Welding Gun FAQs

Q: What's the difference between MIG welding and TIG welding?

A: MIG (Metal Inert Gas) uses a wire electrode and shielding gas for fast, high-deposition welding on thick metals (e.g., steel, aluminum). TIG (Tungsten Inert Gas) uses a non-consumable tungsten electrode for precise, clean welds on thinner materials (e.g., stainless steel, copper).

Q: Why does my MIG gun keep clogging with spatter?

A: Excess spatter is often caused by incorrect voltage/wire speed settings, dirty base metal, or low-quality shielding gas. Clean the workpiece, adjust settings, and use argon/CO2 blends for better results.

Q: Can I use a MIG welder without gas?

A: Yes, with flux-core wire (FCAW), which generates its own shielding gas. Ideal for outdoor welding but produces more smoke and spatter.

Q: How to prevent MIG gun liner wear?

A: Avoid kinking the cable, use the correct liner size for your wire, and replace it annually or if feeding becomes inconsistent.

Q: Best MIG gun for automotive repair?

A: Lightweight, 150–200A guns with flexible necks offer maneuverability for sheet metal and frames.

2. TIG Welding Gun FAQs

Q: Why choose TIG over MIG for aluminum welding?

A: TIG provides finer control over heat input, preventing warping on thin aluminum. Use AC mode with 100% argon gas for clean, oxide-free welds.

Q: How to avoid tungsten contamination in TIG welding?

A: Grind tungsten to a sharp point, avoid touching the workpiece, and use a scratch-start or HF (high-frequency) ignition to prevent sticking.

Q: Can I TIG weld without a foot pedal?

A: Yes, use a lift-arc torch with amperage control on the machine, but a pedal allows real-time adjustments for critical joints.

Q: What gas is best for stainless steel TIG welding?

A: Pure argon for most applications. Add 2–5% helium for thicker materials to increase penetration.

Q: Why does my TIG weld look discolored?

A: Oxidation from inadequate gas coverage. Increase argon flow (15–20 CFH), use a gas lens, and minimize torch angle.

3. Plasma Cutter FAQs

Q: Plasma vs. oxy-acetylene cutting: which is better?

A: Plasma cutters excel on conductive metals (steel, aluminum) up to 1.5" thick with faster, cleaner cuts. Oxy-fuel is better for very thick steel (>2") or heating/bending.
 

Q: How to extend plasma cutter consumable life?
A: Maintain proper air pressure (90–120 PSI), pierce at recommended heights, and avoid dragging the nozzle on the workpiece.

Q: Why does my plasma cutter leave slag/dross?
A: Incorrect amperage, travel speed, or worn consumables. Increase amperage for thicker metal, move faster on thin materials, and replace nozzles regularly.

Q: Can I use a plasma cutter underwater?
A: Yes, underwater cutting reduces heat distortion and fumes. Use a water-injection torch and ensure the machine is rated for submerged operation.

Q: Best plasma cutter for DIY/home use?
A: 30–50A machines handle up to 3/8" steel, are portable, and work on 120V/240V outlets.

4. General Comparison & Safety

Q: MIG vs. TIG vs. Plasma: Which tool do I need?
A: MIG for heavy fabrication/repairs, TIG for precision or exotic metals, and plasma for fast metal cutting. Multi-process machines save cost and space.
 

Q: Safety tips for welding/cutting beginners?
A: Always wear ANSI-approved PPE (helmet, gloves, jacket), work in ventilated areas, and keep a fire extinguisher nearby. Check for gas leaks regularly.