Abstract: Apparatus and methods convert a MIG welder into an effective cutting machine. A plug adaptor is installed into the existing MIG welder gun cup nozzle, which has an inside diameter and a length. A contact tip within the cup has an outside diameter, and shielding gas ports in the cup typically surround the contact tip. The plug adaptor comprises a body having a width dimension corresponding to the inside diameter of the cup, a length corresponding to the length of the cup, and a central bore corresponding to the outer diameter of the contact tip. A channel is established between the width dimension of the body and the inside diameter of the cup enabling air to flow from the shielding gas ports to a workpiece for slag removal produced during the cutting operation. The MIG gun is not modified in any way except for the addition of the removable adaptor.

Abstract: Apparatus and methods convert a MIG welder into an effective cutting machine. A hand-held unit and a feeder supply a wire through the hand-held unit, the wire including a carbon-containing core. A source of electrical energy is connected to the wire being fed and the metal to be cut such that an arc is created with sufficient energy to melt the metal in a localized region, and further apparatus is included for directing a gas to blow away the molten metal. The gas may be air or oxygen. A feedstock for metal cutting operations according to the invention contains a roll of wire having a mild steel jacket and a carbon-containing core. The carbon in the core of the wire may be provided in the form of natural or synthetic graphite powder, and may further include an additive to accelerate delivery force or enhance molten metal flow.