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TIG AND MIG WELDING

End Of Chapter 3 : (CLO4)


EOC 3

NAME: MOHD. FIKRIL HADI B. MOHD. ZAINOL AZLIN


MATRIX CARD NO.: 06PKM12S2007
COURSE: DIP. IN MECHANICAL ENGINEERING
LECTURER: EN. WAN MOHD. RIDZUAN BIN WAN
HUSIN

TABLE OF CONTENTS
CHAPTER

page

1.0

Definition

2.0

Tungsten Inert Gas (TIG) Welding

3.0

Methods of TIG Welding

4.0 Equipments and Electrodes

4.1 Welding torch

4.2 Electrode

5.0 Shielding gas

11

6.0 TIG Weld Defects and How to Avoid Them

12

7.0 MIG Welding (Metal, Inert Gas)

21

8.0 Methods of MIG Welding

23

9.0 Welding Gun And Wire Feed Unit

24

10.0 Tool style

25

11.0 Power supply

25

12.0 Electrode

26

13.0 Shielding gas

27

14.0 Operation

29

15.0 Technique

30

16.0 Quality

30

17.0 MIG Weld Defects on Aluminum and Steel and How to Avoid Them

31

18.0 Conclusion

37

19.0 References

37

1.0 Definition
Arc welding is a type of welding that uses a welding power supply to create an electric
arc between an electrode and the base material to melt the metals at the welding point. They can
use

either direct

(DC)

or

alternating

(AC)

current,

and

consumable

or

non-

consumable electrodes. The welding region is usually protected by some type of shielding gas,
vapour, or slag. Arc welding processes may be manual, semi-automatic, or fully automated. First
developed in the late part of the 19th century, arc welding became commercially important in
shipbuilding during the Second World War. Today it remains an important process for the
fabrication of steel structures and vehicles.

Gas Metal Arc Welding


2.0 Tungsten Inert Gas (TIG) Welding
Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding, is an arc
welding process that uses a non-consumable tungsten electrode to produce the weld. The weld
area is protected from atmospheric contamination by an inert shielding gas(argon or helium), and
a filler metal is normally used, though some welds, known as autogenous welds, do not require
it. A constant-current welding power supply produces energy which is conducted across the arc
through a column of highly ionized gas and metal vapors known as a plasma.
3

GTAW is most commonly used to weld thin sections of stainless steel and non-ferrous metals
such as aluminium, magnesium, copper and alloys. The process grants the operator greater
control over the weld than competing processes such as shielded metal arc welding and gas metal
arc welding, allowing for stronger, higher quality welds. However, GTAW is comparatively more
complex and difficult to master, and furthermore, it is significantly slower than most other
welding techniques. A related process, plasma arc welding, uses a slightly different welding torch
to create a more focused welding arc and as a result is often automated.

3.0 Methods of TIG Welding


Manual gas tungsten arc welding is often considered the most difficult of all the welding
processes commonly used in industry. Because the welder must maintain a short arc length, great
care and skill are required to prevent contact between the electrode and the workpiece. Similar to
torch welding, GTAW normally requires two hands, since most applications require that the
welder manually feed a filler metal into the weld area with one hand while manipulating the
welding torch in the other. However, some welds combining thin materials (known as
autogenous or fusion welds) can be accomplished without filler metal; most notably edge, corner,
and butt joints.
To strike the welding arc, a high frequency generator (similar to a Tesla coil) provides an electric
spark; this spark is a conductive path for the welding current through the shielding gas and
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allows the arc to be initiated while the electrode and the workpiece are separated, typically about
1.53 mm (0.060.12 in) apart. The electric arc produced can reach temperatures of at least
5000 C. This high voltage, high frequency burst can be damaging to some vehicle electrical
systems and electronics, because induced voltages on vehicle wiring can also cause small
conductive sparks in the vehicle wiring or within semiconductor packaging. Vehicle 12V power
may conduct across these ionized paths, driven by the high-current 12V vehicle battery. These
currents can be sufficiently destructive as to disable the vehicle; thus the warning to disconnect
the vehicle battery power from both +12 and ground before using welding equipment on
vehicles.
An alternate way to initiate the arc is the "scratch start". Scratching the electrode against the
work with the power on also serves to strike an arc, in the same way as SMAW ("stick") arc
welding. However, scratch starting can cause contamination of the weld and electrode. Some
GTAW equipment is capable of a mode called "touch start" or "lift arc"; here the equipment
reduces the voltage on the electrode to only a few volts, with a current limit of one or two amps
(well below the limit that causes metal to transfer and contamination of the weld or electrode).
When the GTAW equipment detects that the electrode has left the surface and a spark is present,
it immediately (within microseconds) increases power, converting the spark to a full arc.
Once the arc is struck, the welder moves the torch in a small circle to create a welding pool, the
size of which depends on the size of the electrode and the amount of current. While maintaining
a constant separation between the electrode and the workpiece, the operator then moves the torch
back slightly and tilts it backward about 1015 degrees from vertical. Filler metal is added
manually to the front end of the weld pool as it is needed.
Welders often develop a technique of rapidly alternating between moving the torch forward (to
advance the weld pool) and adding filler metal. The filler rod is withdrawn from the weld pool
each time the electrode advances, but it is never removed from the gas shield to prevent
oxidation of its surface and contamination of the weld. Filler rods composed of metals with low
melting temperature, such as aluminium, require that the operator maintain some distance from
the arc while staying inside the gas shield. If held too close to the arc, the filler rod can melt
before it makes contact with the weld puddle. As the weld nears completion, the arc current is
often gradually reduced to allow the weld crater to solidify and prevent the formation of crater
cracks at the end of the weld.

TIG welding is also very versatile and produces the highest quality welds. It also takes

considerable practice and is least productive.


TIG uses an torch with a tungsten electrode. Argon is used as a shielding gas to protect
weld and tungsten. An arc is struck between the tungsten and the work and a short gap is
maintained. As the weld progresses, filler wire is dipped in the weld pool. Power source

is constant-current DC or AC depending on metal used.


Controlling the torch, feeding wire, moving at the right speed and also using the correct
current makes it physically more complicated. Using a footpedal, you have 1 foot and

both hands busy. It is easier for bench work (I use a barstool)


TIG can do just about any metal with AC and a DC power source. DC is used on ferrous
metals (steels.) AC is used on aluminium. This DIY welder only does DC.

Weld Area

4.0 Equipments and Electrodes

GTAW torch with various electrodes, cups, collets and gas diffusers

GTAW torch, disassembled


The equipment required for the gas tungsten arc welding operation includes a welding torch
utilizing a non-consumable tungsten electrode, a constant-current welding power supply, and a
shielding gas source.

4.1 Welding torch


GTAW welding torches are designed for either automatic or manual operation and are equipped
with cooling systems using air or water. The automatic and manual torches are similar in
construction, but the manual torch has a handle while the automatic torch normally comes with a
mounting rack. The angle between the centerline of the handle and the centerline of the tungsten
electrode, known as the head angle, can be varied on some manual torches according to the
preference of the operator. Air cooling systems are most often used for low-current operations
(up to about 200 A), while water cooling is required for high-current welding (up to about
600 A). The torches are connected with cables to the power supply and with hoses to the
shielding gas source and where used, the water supply.

The internal metal parts of a torch are made of hard alloys of copper or brass in order to transmit
current and heat effectively. The tungsten electrode must be held firmly in the center of the torch
with an appropriately sized collet, and ports around the electrode provide a constant flow of
shielding gas. Collets are sized according to the diameter of the tungsten electrode they hold. The
body of the torch is made of heat-resistant, insulating plastics covering the metal components,
providing insulation from heat and electricity to protect the welder.
The size of the welding torch nozzle depends on the amount of shielded area desired. The size of
the gas nozzle will depend upon the diameter of the electrode, the joint configuration, and the
availability of access to the joint by the welder. The inside diameter of the nozzle is preferably at
least three times the diameter of the electrode, but there are no hard rules. The welder will judge
the effectiveness of the shielding and increase the nozzle size to increase the area protected by
the external gas shield as needed. The nozzle must be heat resistant and thus is normally made
of alumina or a ceramic material, but fused quartz, a high purity glass, offers greater visibility.
Devices can be inserted into the nozzle for special applications, such as gas lenses or valves to
improve the control shielding gas flow to reduce turbulence and introduction of contaminated
atmosphere into the shielded area. Hand switches to control welding current can be added to the
manual GTAW torches.

4.2 Electrode

The electrode used in GTAW is made of tungsten or a tungsten alloy, because tungsten has the
highest melting temperature among pure metals, at 3,422 C (6,192 F). As a result, the electrode
is not consumed during welding, though some erosion (called burn-off) can occur. Electrodes can
have either a clean finish or a ground finishclean finish electrodes have been chemically
cleaned, while ground finish electrodes have been ground to a uniform size and have a polished
surface, making them optimal for heat conduction. The diameter of the electrode can vary
between 0.5 and 6.4 millimetres (0.02 and 0.25 in), and their length can range from 75 to 610
millimetres (3.0 to 24.0 in).
A number of tungsten alloys have been standardized by the International Organization for
Standardization and the American Welding Society in ISO 6848 and AWS A5.12, respectively,
for use in GTAW electrodes, and are summarized in the adjacent table.

Pure tungsten electrodes (classified as WP or EWP) are general purpose and low cost
electrodes. They have poor heat resistance and electron emission. They find limited use in
AC welding of e.g. magnesium and aluminium.

Cerium oxide (or ceria) as an alloying element improves arc stability and ease of starting
while decreasing burn-off. Cerium addition is not as effective as thorium but works well, and
cerium is not radioactive.

Using an alloy of lanthanum oxide (or lanthana) has a similar effect. Addition of 1%
lanthanum has the same effect as 2% of cerium.

Thorium oxide (or thoria) alloy electrodes were designed for DC applications and can
withstand somewhat higher temperatures while providing many of the benefits of other
alloys. However, it is somewhat radioactive. Inhalation of the thorium grinding dust during
preparation of the electrode is hazardous to one's health. As a replacement to thoriated
electrodes, electrodes with larger concentrations of lanthanum oxide can be used. Larger
additions than 0.6% do not have additional improving effect on arc starting, but they help
with electron emission. Higher percentage of thorium also makes tungsten more resistant to
contamination.

Electrodes containing zirconium oxide (or zirconia) increase the current capacity while
improving arc stability and starting and increasing electrode life. Zirconium-tungsten
electrodes melt easier than thorium-tungsten.

In addition, electrode manufacturers may create alternative tungsten alloys with specified
metal additions, and these are designated with the classification EWG under the AWS
system.

Filler metals are also used in nearly all applications of GTAW, the major exception being the
welding of thin materials. Filler metals are available with different diameters and are made of a
variety of materials. In most cases, the filler metal in the form of a rod is added to the weld pool

manually, but some applications call for an automatically fed filler metal, which often is stored
on spools or coils.

ISO

ISO

AWS

AWS

Alloy

Class

Color

Class

Color

WP

Green

EWP

Green

WC20 Gray

EWCe-2

Orange ~2% CeO2

WL10 Black

EWLa-1

Black

WL15 Gold

EWLa-1.5 Gold

None

~1% La2O3
~1.5% La2O3

WL20 Sky-blue EWLa-2

Blue

~2% La2O3

WT10 Yellow

EWTh-1

Yellow

~1% ThO2

WT20 Red

EWTh-2

Red

~2% ThO2

WT30 Violet

~3% ThO2

WT40 Orange

~4% ThO2

WY20 Blue

~2% Y2O3

WZ3

Brown

WZ8

White

EWZr-1

Brown

~0.3% ZrO2
~0.8% ZrO2

Table of Electrodes

10

5.0 Shielding gas

GTAW System Setup


As with other welding processes such as gas metal arc welding, shielding gases are necessary in
GTAW to protect the welding area from atmospheric gases such as nitrogen and oxygen, which
can cause fusion defects, porosity, and weld metal embrittlement if they come in contact with the
electrode, the arc, or the welding metal. The gas also transfers heat from the tungsten electrode to
the metal, and it helps start and maintain a stable arc.
The selection of a shielding gas depends on several factors, including the type of material being
welded, joint design, and desired final weld appearance. Argon is the most commonly used
shielding gas for GTAW, since it helps prevent defects due to a varying arc length. When used
with alternating current, the use of argon results in high weld quality and good appearance.
Another common shielding gas, helium, is most often used to increase the weld penetration in a
joint, to increase the welding speed, and to weld metals with high heat conductivity, such as
copper and aluminum. A significant disadvantage is the difficulty of striking an arc with helium
gas, and the decreased weld quality associated with a varying arc length.
Argon-helium mixtures are also frequently utilized in GTAW, since they can increase control of
the heat input while maintaining the benefits of using argon. Normally, the mixtures are made
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with primarily helium (often about 75% or higher) and a balance of argon. These mixtures
increase the speed and quality of the AC welding of aluminum, and also make it easier to strike
an arc. Another shielding gas mixture, argon-hydrogen, is used in the mechanized welding of
light gauge stainless steel, but because hydrogen can cause porosity, its uses are limited.
Similarly, nitrogen can sometimes be added to argon to help stabilize the austenite in austentitic
stainless steels and increase penetration when welding copper. Due to porosity problems in
ferritic steels and limited benefits, however, it is not a popular shielding gas additive.

6.0 TIG Weld Defects and How to Avoid Them


Gas Tungsten Arc Welding (GTAW), or TIG, is often specified to meet strict aesthetic, structural,
or code/standard requirements. The TIG process is complex, and it is undisputedly the most
difficult process to learn. This article contains photos and descriptions of common TIG mistakes
and basic tips on how to prevent these errors from happening.
Figure 1 Poor Gas Coverage Leads to Contamination
The weld here shows contamination caused by lack of shielding gas, which can happen when the
shielding gas is not turned on, there is either too little or too much gas shielding, or the gas
shielding is blown away.

Figure 1: Poor gas coverage leads to contamination


To troubleshoot gas contamination issues, first check the gas cylinder label to be sure youre
using the right type of gas for TIG welding, generally 100 percent argon (or perhaps an

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argon/helium blend for thick aluminum). Attempting to weld with an AR/CO2 mix (used for
MIG welding) will cause immediate contamination.
Next, set the proper gas flow rate, which should be 15 to 20 cubic feet per hour (cfh). Welders
commonly and incorrectly assume that a higher gas flow/pressure provides greater protection. In
fact, excessive gas flow creates turbulence and swirling currents that pull in unwanted airborne
contaminants (and it can cause arc wandering). Generally, err on the lower side of recommended
shielding gas rates to ensure proper shielding coverage without turbulence.
Third, check all the fittings and hoses for leaks. Any breach may pull air into the shielding gas
stream, which can cause the weld to be contaminated (and youll waste money if gas escapes).
Rub soapy water over the hose and all fittings. If bubbles form, you have a leak and need to
replace the defective components.
Finally, assuming you have a full cylinder, the right type of gas and no leaks, consider that you
may have a tank contaminated with moisture. Shielding gas cylinder contamination does not
happen frequently, but it is possible. Check with your gas supplier to resolve this issue.
Figure 2A-2D Welding Aluminum in the Wrong Polarity/Adjusting Balance
This TIG weld (Figure 2A) was created with the machines polarity set on direct current
electrode negative (DCEN). As you can see, the weld did not break through the aluminum oxide
layer. This created a weld where the filler metal mixed in with the partially melted oxide and
created the contaminated bead seen here. To defeat this, always TIG weld aluminum with the
polarity set to alternating current (AC).

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TIG welding in AC (Figure 2B) allows the


electrode positive (EP) portion of the cycle to
blast away the aluminum oxide while the
electrode negative (EN) portion melts the base
metal. A feature called AC balance control
allows operators to tailor the EP to EN ratio. If
Figure 2A: Aluminum welded in DC with argon you notice a brownish oxidation and or flakes
that look like black pepper in your weld puddle
(Figure 2C), increase the cleaning action.
However, note that too much EP causes the
tungsten to ball excessively (Figure 2D) and
provides too much etching. Lastly, when TIG
welding aluminum, do not start welding until
the puddle has the appearance of a shiny dot.
Figure 2B: Ideal aluminum weld

This indicates that the oxide has been removed


and it is safe to add filler and move forward.
Adding filler to the weld zone before the oxide
layer is adequately removed will result in
contamination.
Figures 2B and 3 Weld Graininess
Figure 2B shows the way an aluminum TIG
bead should look. Figure 3 shows a bead with a

Figure 2C: AC balance set too high

grainy appearance, which is typically caused by


filler metal problems. For instance, a 4043
aluminum filler rod from one manufacturer
may have different properties than a 4043 rod
from another manufacturer. The welder (if the
application permits) may need to adjust filler
brand accordingly. The rod may also be

Figure 2D: balled tungsten

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defective (too much of a certain ingredient). The welder may even have the wrong type of filler
rod, such as 4043 filler instead of 5356 filler.
Prior to welding, always check the filler metal type and remove all grease, oil and moisture from
the surface to prevent contamination.
Figure 4 Lack of Fusion in the Root
Lack of fusion at the root of a T-joint or a fillet weld can be caused by a number of factors:
improper fit-up, holding the torch too far away from the joint (increasing arc length) and
improperly feeding the filler rod, to name a few. This issue may be seen more often with a
transformer-based machine, as the arc tends to wander between the two sides of the joint as it
seeks the path of least resistance. In this case, reducing arc length will provide better directional
control and help increase penetration. It is also important not to under-fill the joint or weld too
quickly.
Note that inverter-based machines (especially those with an advanced output controls such as
adjustable frequency and pulsing controls) offer more control over the arc. These controls create
a narrower, more focused arc cone that provides better directional control over the weld puddle
and deeper penetration (and often at increased travel speeds).
Figure 5A and 5B Craters
Craters, such as the one shown in Figure 5A, typically occur at the end of the weld, and they
often lead to cracking. Causes include instantly reducing the welding power (which causes the
puddle to cool too quickly) and removing the filler rod too quickly at the end of the weld. You
can easily fix crater cracking issues by continuing to feed filler rod while slowly reducing current
at the end of a weld. Note that some TIG welders feature a crater control function that
automatically reduces the current at the end of a weld. The result is a good-looking weld bead, as
seen in Figure 5B.

15

Figure 6A through 6D Dirty Base and/or Filler Metal


On day one of welding school, your instructor should have taught you to clean materials prior to
welding. This photo (Figure 6A) shows what happens when you dont clean the mill scale off of
hot-rolled mild steel. All base and filler metals need to be cleaned, whether its mill scale, oxide
on aluminum, or dirt and grease on filler metals. Grind, brush and wipe away all potential
contaminants. For cleaning aluminum, dedicate a stainless steel brush to the task to prevent
contamination from other metals.
Figure 6B shows what happens when a weld on mild steel has been properly cleaned before
welding. Figure 6C shows a weld made on chrome-moly tubing that has not been cleaned, hile
6D shows a weld made that has been cleaned prior to welding.

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Figure 6A: Uncleaned steel weld

Figure 6B: Clean steel weld

Figure 6C: Uncleaned Chrome Moly

Figure 6D: Cleaned chrome moly


Figure 7A and 7B Poor Color on Stainless
Figure 7A shows discoloration on a stainless steel weld caused by overheating, which not only
affects a materials color, but degrades its corrosion resistance and mechanical properties as well.
Unfortunately, once this error is made, there is nothing that can be done to fix it except for
scrapping the part and starting over. To prevent overheating, reduce amperage, slightly increase
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travel speed or shorten the arc length. If your welding equipment features pulsing capabilities,
now is the time to learn how to use them. Pulsing reduces heat input, and it offers excellent
control of the weld puddle. Figure 7B shows proper coloration of stainless.

Figure 7A: Poor color on stainless steel

Figure 7B: Good color on stainless steel


Figure 8 Sugaring on Stainless
Figure 8 shows sugaring on the backside of a stainless steel weld. Sugaring (oxidation) occurs
around the weld when it is exposed to oxygen in the air. The best way to prevent sugaring is to
back purge the weld with argon shielding gas or reduce welding amperage.

18

Figure 8: Sugaring on stainless steel


Figure 9 Too Much Amperage on Aluminum
Figure 9A shows what a weld bead looks like on aluminum with the amperage set too high. This
creates a wider profile, an ill-defined bead and can potentially lead to burn-through. To solve this
problem, reduce amperage and/or increase travel speed. Reference back to Figure 2B to identify
an ideal weld.

Figure 9: Excessive amperage/heat input


Figure 10 Proper Arc Length Control
The color change in the middle of this aluminum weld bead (Figure 10) resulted from an increase
in arc length (arc length, the distance between the electrode and the base metal, determines TIG
welding voltage). Holding too long of an arc increases overall heat input, increases the potential
for distortion, widens the weld bead while decreasing penetration and affects weld bead
appearance. Practice holding a consistent arc length to improve heat input control and improve
weld bead quality.

Figure 10: Change in arc length


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Solidification Cracking
This is also called centreline or hot cracking. They are called hot cracks because they occur
immediately after welds are completed and sometimes while the welds are being made. These
defects, which are often caused by sulphur and phosphorus, are more likely to occur in higher
carbon steels.
Solidification cracks are normally distinguishable from other types of cracks by the following
features:

they occur only in the weld metal - although the parent metal is almost always the source
of the low melting point contaminants associated with the cracking

they normally appear in straight lines along the centreline of the weld bead, but may
occasionally appear as transverse cracking

solidification cracks in the final crater may have a branching appearance

as the cracks are 'open' they are visible to the naked eye

A schematic diagram of a centreline crack is shown below:

On breaking open the weld the crack surface may have a blue appearance, showing the cracks
formed while the metal was still hot. The cracks form at the solidification boundaries and are
characteristically inter dendritic. There may be evidence of segregation associated with the
solidification boundary.
The main cause of solidification cracking is that the weld bead in the final stage of solidification

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has insufficient strength to withstand the contraction stresses generated as the weld pool
solidifies. Factors which increase the risk include:

insufficient weld bead size or inappropriate shape

welding under excessive restraint

material properties - such as a high impurity content or a relatively large shrinkage on


solidification

Joint design can have an influence on the level of residual stresses. Large gaps between
components will increase the strain on the solidifying weld metal, especially if the depth of
penetration is small. Hence weld beads with a small depth to width ratio, such as is formed when
bridging a large wide gap with a thin bead, will be more susceptible to solidification cracking.
In steels, cracking is associated with impurities, particularly sulphur and phosphorus and is
promoted by carbon, whereas manganese and sulphur can help to reduce the risk. To minimise
the risk of cracking, fillers with low carbon and impurity levels and a relatively high manganese
content are preferred. As a general rule, for carbon manganese steels, the total sulphur and
phosphorus content should be no greater than 0.06%. However when welding a highly restrained
joint using high strength steels, a combined level below 0.03% might be needed.
Weld metal composition is dominated by the filler and as this is usually cleaner than the metal
being welded, cracking is less likely with low dilution processes such as MMA and MIG. Parent
metal composition becomes more important with autogenous welding techniques, such as TIG
with no filler.

7.0 MIG Welding (Metal, Inert Gas)


MIG welding (Metal, Inert Gas) welding is also call GMAW (Gas, Metal Arc Welding.) It uses a
thin wire as an electrode and filler fed by a wire feeder to the gun. The power source is constant
voltage (CV) DC. Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal
inert gas (MIG) welding or metal active gas (MAG) welding, is a welding process in which an
electric arc forms between a consumable wire electrode and the workpiece metal(s), which heats
the workpiece metal(s), 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
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the air. The process can be semi-automatic or automatic. A constant voltage, direct current power
source is most commonly used with GMAW, but constant current systems, as well as alternating
current, can be used. There are four primary methods of metal transfer in GMAW, called
globular, short-circuiting, spray, and pulsed-spray, each of which has distinct properties and
corresponding advantages and limitations.
Originally developed for welding aluminium and other non-ferrous materials in the 1940s,
GMAW was soon applied to steels because it provided faster welding time compared to other
welding processes. The cost of inert gas limited its use in steels until several years later, when the
use of semi-inert gases such as carbon dioxide became common. Further developments during
the 1950s and 1960s gave the process more versatility and as a result, it became a highly used
industrial process. Today, GMAW is the most common industrial welding process, preferred for
its versatility, speed and the relative ease of adapting the process to robotic automation. Unlike
welding processes that do not employ a shielding gas, such as shielded metal arc welding, it is
rarely used outdoors or in other areas of air volatility. A related process, flux cored arc welding,
often does not use a shielding gas, but instead employs an electrode wire that is hollow and filled
with flux.

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There are two main process Gas (MIG) and gasless (flux core). Below is a comparison of

the two:
Gasless MIG (FCAW - Flux Core Arc Welding):

Does not need shielding gas, saves cost of bottles, regulator.

Wire is more expensive.

It is more portable, no gas to transport.

Uses flux core to shield weld. Causes slag and spatter that must be cleaned up.

Produces smoke that makes it hard to see weld.

Has deeper penetration than gas MIG.

Easier on positional welds (overhead and vertical.)

Direct-Current, Electrode Negative Polarity (DCEN)

Smallest wire available is 0.030" (0.8mm); not easy to use on thin metal.

Gas MIG (GMAW):

Very clean welds with no slag or spatter.

Uses Argon/CO2 or straight CO2 as a shielding gas.

Wire is less expensive.

More complex than Flux Core

Less portable

Direct-Current, Electrode Positive polarity (DCEP)

Wire size down to 0.023: (0.6mm), great for thin metal.

8.0 Methods of MIG Welding

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The wire is fed via from a roll wire feeder to the gun. MIG is the easiest process to learn, but
requires gas and a wire feeder so it is not as portable. MIG is great for thin metal especially
auto body work.

To perform gas metal arc welding, the basic necessary equipment is a welding gun, a wire
feed unit, a welding power supply, an electrode wire, and a shielding gas supply.

9.0 Welding Gun And Wire Feed Unit


GMAW torch nozzle cutaway image. (1) Torch
handle, (2) Molded phenolic dielectric (shown
in white) and threaded metal nut insert
(yellow), (3)Shielding gas diffuser, (4) Contact
tip, (5) Nozzle output face

GMAW on stainless steel


The typical GMAW welding gun has a number
of key partsa control switch, a contact tip, a power cable, a gas nozzle, an electrode conduit
and liner, and a gas hose. The control switch, or trigger, when pressed by the operator,
initiates the wire feed, electric power, and the shielding gas flow, causing an electric arc to be
struck. The contact tip, normally made of copper and sometimes chemically treated to reduce
spatter, is connected to the welding power source through the power cable and transmits the
electrical energy to the electrode while directing it to the weld area. It must be firmly secured
and properly sized, since it must allow the electrode to pass while maintaining electrical
contact.

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On the way to the contact tip, the wire is protected and guided by the electrode conduit and
liner, which help prevent buckling and maintain an uninterrupted wire feed. The gas nozzle
directs the shielding gas evenly into the welding zone. Inconsistent flow may not adequately
protect the weld area. Larger nozzles provide greater shielding gas flow, which is useful for
high current welding operations that develop a larger molten weld pool. A gas hose from the
tanks of shielding gas supplies the gas to the nozzle. Sometimes, a water hose is also built
into the welding gun, cooling the gun in high heat operations.
The wire feed unit supplies the electrode to the work, driving it through the conduit and on to
the contact tip. Most models provide the wire at a constant feed rate, but more advanced
machines can vary the feed rate in response to the arc length and voltage. Some wire feeders
can reach feed rates as high as 30.5 m/min (1200 in/min), but feed rates for semiautomatic
GMAW typically range from 2 to 10 m/min (75400 in/min).
10.0 Tool style
The top electrode holder is a semiautomatic air-cooled holder. Compressed air circulates
through it to maintain moderate temperatures. It is used with lower current levels for welding
lap or butt joints. The second most common type of electrode holder is semiautomatic watercooled, where the only difference is that water takes the place of air. It uses higher current
levels for welding T or corner joints. The third typical holder type is a water cooled automatic
electrode holderwhich is typically used with automated equipment.
11.0 Power supply
Most applications of gas metal arc welding use a constant voltage power supply. As a result,
any change in arc length (which is directly related to voltage) results in a large change in heat
input and current. A shorter arc length causes a much greater heat input, which makes the
wire electrode melt more quickly and thereby restore the original arc length. This helps
operators keep the arc length consistent even when manually welding with hand-held welding
guns. To achieve a similar effect, sometimes a constant current power source is used in
combination with an arc voltage-controlled wire feed unit. In this case, a change in arc length
25

makes the wire feed rate adjust to maintain a relatively constant arc length. In rare
circumstances, a constant current power source and a constant wire feed rate unit might be
coupled, especially for the welding of metals with high thermal conductivities, such as
aluminum. This grants the operator additional control over the heat input into the weld, but
requires significant skill to perform successfully.
Alternating current is rarely used with GMAW; instead, direct current is employed and the
electrode is generally positively charged. Since the anode tends to have a greater heat
concentration, this results in faster melting of the feed wire, which increases weld penetration
and welding speed. The polarity can be reversed only when special emissive-coated electrode
wires are used, but since these are not popular, a negatively charged electrode is rarely
employed.
12.0 Electrode
Electrode selection is based primarily on the composition of the metal being welded, the
process variation being used, joint design and the material surface conditions. Electrode
selection greatly influences the mechanical properties of the weld and is a key factor of weld
quality. In general the finished weld metal should have mechanical properties similar to those
of the base material with no defects such as discontinuities, entrained contaminants or
porosity within the weld. To achieve these goals a wide variety of electrodes exist. All
commercially

available

electrodes

contain

deoxidizing

metals

such

as silicon, manganese, titanium and aluminum in small percentages to help prevent oxygen
porosity. Some contain denitriding metals such as titanium and zirconium to avoid nitrogen
porosity.[11] Depending on the process variation and base material being welded the diameters
of the electrodes used in GMAW typically range from 0.7 to 2.4 mm (0.0280.095 in) but can
be as large as 4 mm (0.16 in). The smallest electrodes, generally up to 1.14 mm (0.045 in)
[12]

are associated with the short-circuiting metal transfer process, while the most common

spray-transfer process mode electrodes are usually at least 0.9 mm (0.035 in).

26

GMAW Circuit diagram. (1) Welding torch,(2) Workpiece, (3) Power source, (4) Wire feed
unit, (5) Electrode source, (6) Shielding gas supply.
13.0 Shielding gas
Shielding gases are necessary for gas metal arc welding to protect the welding area from
atmospheric gases such as nitrogen and oxygen, which can cause fusion defects, porosity, and
weld metal embrittlement if they come in contact with the electrode, the arc, or the welding
metal. This problem is common to all arc welding processes; for example, in the older
Shielded-Metal Arc Welding process (SMAW), the electrode is coated with a solid flux which
evolves a protective cloud of carbon dioxide when melted by the arc. In GMAW, however,
the electrode wire does not have a flux coating, and a separate shielding gas is employed to
protect the weld. This eliminates slag, the hard residue from the flux that builds up after
welding and must be chipped off to reveal the completed weld.
The choice of a shielding gas depends on several factors, most importantly the type of
material being welded and the process variation being used. Pure inert gases such
as argon and helium are only used for nonferrous welding; with steel they do not provide
adequate weld penetration (argon) or cause an erratic arc and encourage spatter (with
helium). Pure carbon dioxide, on the other hand, allows for deep penetration welds but
encourages oxide formation, which adversely affect the mechanical properties of the weld. lts
low cost makes it an attractive choice, but because of the reactivity of the arc plasma, spatter
is unavoidable and welding thin materials is difficult. As a result, argon and carbon dioxide
27

are frequently mixed in a 75%/25% to 90%/10% mixture. Generally, in short circuit GMAW,
higher carbon dioxide content increases the weld heat and energy when all other weld
parameters (volts, current, electrode type and diameter) are held the same. As the carbon
dioxide content increases over 20%, spray transfer GMAW becomes increasingly
problematic, especially with smaller electrode diameters.
Argon is also commonly mixed with other gases, oxygen, helium, hydrogen, and nitrogen.
The addition of up to 5% oxygen (like the higher concentrations of carbon dioxide mentioned
above) can be helpful in welding stainless steel, however, in most applications carbon dioxide
is preferred. Increased oxygen makes the shielding gas oxidize the electrode, which can lead
to porosity in the deposit if the electrode does not contain sufficient deoxidizers. Excessive
oxygen, especially when used in application for which it is not prescribed, can lead to
brittleness in the heat affected zone. Argon-helium mixtures are extremely inert, and can be
used on nonferrous materials. A helium concentration of 50%75% raises the required
voltage and increases the heat in the arc, due to helium's higher ionization temperature.
Hydrogen is sometimes added to argon in small concentrations (up to about 5%) for welding
nickel and thick stainless steel workpieces. In higher concentrations (up to 25% hydrogen), it
may be used for welding conductive materials such as copper. However, it should not be used
on steel, aluminium or magnesium because it can cause porosity and hydrogen embrittlement.
Shielding gas mixtures of three or more gases are also available. Mixtures of argon, carbon
dioxide and oxygen are marketed for welding steels. Other mixtures add a small amount of
helium to argon-oxygen combinations, these mixtures are claimed to allow higher arc
voltages and welding speed. Helium also sometimes serves as the base gas, with small
amounts of argon and carbon dioxide added. However, because it is less dense than air,
helium is less effective at shielding the weld than argonwhich is denser than air. It also can
lead to arc stability and penetration issues, and increased spatter, due to its much more
energetic arc plasma. Helium is also substantially more expensive than other shielding gases.
Other specialized and often proprietary gas mixtures claim even greater benefits for specific
applications. The desirable rate of shielding-gas flow depends primarily on weld geometry,
28

speed, current, the type of gas, and the metal transfer mode. Welding flat surfaces requires
higher flow than welding grooved materials, since gas disperses more quickly. Faster welding
speeds, in general, mean that more gas must be supplied to provide adequate coverage.
Additionally, higher current requires greater flow, and generally, more helium is required to
provide adequate coverage than if argon is used. Perhaps most importantly, the four primary
variations of GMAW have differing shielding gas flow requirementsfor the small weld
pools of the short circuiting and pulsed spray modes, about 10 L/min (20 ft/h) is generally
suitable, whereas for globular transfer, around 15 L/min (30 ft/h) is preferred. The spray
transfer variation normally requires more shielding-gas flow because of its higher heat input
and thus larger weld pool. Typical gas-flow amounts are approximately 2025 L/min (40
50 ft/h).

14.0 Operation

GMAW weld area. (1) Direction of travel, (2) Contact tube, (3) Electrode, (4) Shielding
gas, (5) Molten weld metal, (6) Solidified weld metal, (7) Workpiece.
For most of its applications gas metal arc welding is a fairly simple welding process to learn
requiring no more than a week or two to master basic welding technique. Even when welding
is performed by well-trained operators weld quality can fluctuate since it depends on a
number of external factors. All GMAW is dangerous, though perhaps less so than some other
welding methods, such as shielded metal arc welding.
29

15.0 Technique
The basic technique for GMAW is quite simple, since the electrode is fed automatically
through the torch (head of tip). By contrast, in gas tungsten arc welding, the welder must
handle a welding torch in one hand and a separate filler wire in the other, and in shielded
metal arc welding, the operator must frequently chip off slag and change welding electrodes.
GMAW requires only that the operator guide the welding gun with proper position and
orientation along the area being welded. Keeping a consistent contact tip-to-work distance
(the stick out distance) is important, because a long stickout distance can cause the electrode
to overheat and also wastes shielding gas.
Stickout distance varies for different GMAW weld processes and applications.

The

orientation of the gun is also importantit should be held so as to bisect the angle between
the workpieces; that is, at 45 degrees for a fillet weld and 90 degrees for welding a flat
surface. The travel angle, or lead angle, is the angle of the torch with respect to the direction
of travel, and it should generally remain approximately vertical. However, the desirable angle
changes somewhat depending on the type of shielding gas usedwith pure inert gases, the
bottom of the torch is often slightly in front of the upper section, while the opposite is true
when the welding atmosphere is carbon dioxide.

16.0 Quality
Two of the most prevalent quality problems in GMAW are dross and porosity. If not
controlled, they can lead to weaker, less ductile welds. Dross is an especially common
problem in aluminium GMAW welds, normally coming from particles of aluminium oxide or
aluminium nitride present in the electrode or base materials. Electrodes and workpieces must
be brushed with a wire brush or chemically treated to remove oxides on the surface. Any
oxygen in contact with the weld pool, whether from the atmosphere or the shielding gas,
causes dross as well. As a result, sufficient flow of inert shielding gases is necessary, and
welding in volatile air should be avoided.
In GMAW the primary cause of porosity is gas entrapment in the weld pool, which occurs
when the metal solidifies before the gas escapes. The gas can come from impurities in the
shielding gas or on the workpiece, as well as from an excessively long or violent arc.
Generally, the amount of gas entrapped is directly related to the cooling rate of the weld pool.
30

Because of its higher thermal conductivity, aluminium welds are especially susceptible to
greater cooling rates and thus additional porosity. To reduce it, the workpiece and electrode
should be clean, the welding speed diminished and the current set high enough to provide
sufficient heat input and stable metal transfer but low enough that the arc remains
steady. Preheating can also help reduce the cooling rate in some cases by reducing the
temperature gradient between the weld area and the base material.

17.0 MIG Weld Defects on Aluminum and Steel and How to Avoid Them
Some of the most common weld defects are porosity, lack of fusion and burn through, with
aluminum presenting a few more welding challenges than steel. Aluminum conducts heat
about six times faster than steel, plus it has excellent thermal conductivity coupled with a low
melting point, making it extremely susceptible to warping and burn-through. Additionally,
aluminum wire has less tensile strength, which can pose wire feeding issues and lead to weld
defects if the correct equipment is not used. We'll highlight the differences here.
Porosity:
Shielding gas protects the molten weld pool from the surrounding atmosphere, which would
otherwise contaminate the weld. Figure 1 shows how the lack of shielding gas on steel can
cause porosity (pinholes) in the weld bead are formed in the face and weld interior in the
absence of shielding gas. Lack of shielding gas can be caused by improper setting on the
equipment, a hole in the gun liner or wind blowing the shielding gas away.

FIG. 1. No Shielding Gas on Steel - A lack of or inadequate shielding gas is easily identified
by the porosity and (pinholes) in the face and interior of the weld.
31

FIG. 2
On aluminum, a sooty looking weld (FIG.2) can be caused by using a drag vs. a push
technique (FIG. 3, below). The soot can be removed, but cutting the weld open will reveal
pinholes where impurities are trapped in the weld. Aluminum builds up an oxide that needs to
be removed before welding. Wire brushing is the most common method of cleaning
aluminum, but it needs to be done with a stainless steel brush to avoid contaminating the
weld with the impurities of a steel brush.

FIG. 3.
Push vs. drag technique. On steel, either pushing or dragging the gun is acceptable, but with
aluminum, the drag technique will lead to weld defects.

32

Lack of Fusion
Lack of fusion can occur when the voltage or wire feed speed is set too low, or when the
operator's travel speed is too fast. Because aluminum conducts heat much faster than steel, it
is prone to lack of fusion at the start of a weld until enough energy is put into the weld. Some
welding equipment addresses this by automatically ramping up the current at the start of a
weld and then decreasing it to avoid too much heat build up.
Craters
With aluminum, craters can form at the end of a weld. If they are not filled in, they create a
stress point, which can lead to cracking. This requires the user to quickly trigger the gun
again to fill in the crater, although some welding machines offer a crater timer that will fill in
the crater when the gun trigger is released.
Burn Through
Too much heat input can be caused by setting voltage or wire feed speed too high or by too
slow of a travel speed. This can lead to warping or burn through especially on the thinner
materials found in the sign industry, aluminum being more prone to the effects than steel.
Generally aluminum requires a faster travel speed than steel to avoid heat build up.
Feeding aluminum
Because of its low columnar strength, feeding aluminum wire has been likened to pushing a
wet noodle through a straw. "Birdnesting," or the tangling of the wire between the drive roll
and the liner is a common, time-consuming and costly problem. Clearing it requires the
operator to stop welding, cut the wire, discard the wire in the gun, and refeed new wire
through the liner. It also may require cleaning or changing the contact tip because of the
burnback caused when the wire stops feeding. There are several ways to feed aluminum wire:
Push only, spool gun, push-pull system and continuous feed push only system.
Push only: Feeding aluminum wire through a push only system can be difficult, but it can be
done on a limited basis. It requires u-groove drive rolls to provide more surface contact with
the wire, a Teflon liner, adequate drive-roll pressure, the ability to keep the gun cable straight
and a high tolerance for pain.

33

Spool Gun: A spool gun, such as the Spoolmatic 15A or 30A, eliminates the possibility of
birdnesting by putting a 4-inch (1-lb.) spool on the gun, so the wire only feeds a few inches.
Spool guns can accommodate aluminum wire diameters from .023 to 1/16-inch and allow the
operator to use longer cables (15'-50').
A spool gun needs to have the roll changed after every pound of wire is used, compared with
the 8- or 15 lb spool on a push-pull system.
Push-pull gun: With a push-pull gun, a motor in the gun pulls the wire through the liner,
while the motor in the welder or feeder control becomes an assist motor. By maintaining
consistent tension on the wire, the push-pull system helps eliminate birdnesting. It is more
ergonomic than the spool gun, since the weight of the spool is not in the operator's hands.
Also, the spool needs to be changed less often than on a spool gun and allows the purchase of
larger spools. However, remember that aluminum builds up an oxide layer after being
exposed to air for a while. If you only go through a pound or two of aluminum a week, the
smaller spool may be a better choice.
Choosing the right equipment
Choosing the right equipment can address many of these problems before they occur.
AutoSetTMtechnology, as found on many of Miller's Millermatic welders, relieves the operator
of having to dial in parameters when welding steel. With Auto-Set, the operator simply dials
in the thickness of the steel and the diameter of the wire being used, and the machine sets the
optimal voltage and wire feed speed.
For fine tuning, or for welding aluminum, a machine equipped with infinite voltage control,
such as the Millermatic 212 AutoSet or Millermatic 252, allows the operator to fine tune
settings to avoid putting too much or too little heat into the weld. Older equipment may use
tapped settings that can make it more difficult to set, especially when welding thin material.
In addition, both the Millermatic 212 and Millermatic 252 can use spool guns to allow easy
set up for both steel and aluminum welding. The Millermatic 252 also features Auto Gun
DetectTM, so the operator only has to pick up the MIG or spool gun and pull the trigger to start
welding.

34

For more dedicated aluminum welding, a machine such as the Millermatic 350P, features
pulsed MIG welding, which helps eliminate burn through on thin materials. In addition, it
features an XR-Aluma-ProTM push-pull gun, which helps eliminate wire feeding issues.
Additional technology, such as Aluminum Pulse Hot Start TM provides more power at the start
of a weld to avoid the "cold start" to which aluminum welding is prone.

Troubleshooting

The photo above shows an example of a good weld on steel. Below are photos of a selection
of bad welds that can result from a variety of potential problems, including the following:

Voltage Too Low - Too little voltage results in poor arc starts, control and penetration. It also
causes excessive spatter, a convex bead profile, and poor tie-in at the toes of the weld.

35

Wire Feed Speed/Amperage Too High - Setting the wire feed speed or amperage too high
(depending on what type of machine you're using) can cause poor arc starts and lead to an
excessively wide weld bead, burn-through and distortion.

Wire Feed Speed/Amperage Too Low - A narrow, oftentimes convex bead with poor tie-in
at the toes of the weld marks insufficient amperage.

Travel Speed Too Fast - A narrow convex bead with inadequate tie-in at the toes of the weld,
insufficient penetration and an inconsistent weld bead are caused by traveling too fast.

Travel Speed Too Slow - Traveling too slowly may produce a large weld with excessive heat
input resulting in heat distortion and possible burn through. In most cases, proper travel speed
is when the arc is on the leading edge of the puddle.

Voltage Too High: Too much voltage is marked by poor arc control, inconsistent penetration,
and a turbulent weld pool that fails to consistently penetrate the base material.
36

18.0 Conclusion
The MIG welding process - metal inert gas welding, or MAG - metal active gas welding, is
the one mainly used for our applications. The consumable welding wire is fed by a motor
with variable speed. At the same time a nozzle above the weld discharges the gas required, to
prevent the molten metal beneath the arc from oxidizing. Using different compositions of gas
(pure CO2 or gas mixture Argon + CO2) the welding process can be actively affected and
adapted according to material. Roughly speaking one can say that the MAG process is used
for steel and the MIG process for nonferrous metals.
The great advantage of TIG Welding process is that it facilitates the spatter-free joining
together of any fusion weldable material. Voltage and filler are decoupled, since this process
works without a consumable electrode. As a result of the reduced heat input, welding
distortion is markedly reduced compared to other welding processes. Suitable gases are
argon, helium or a mixture of the two. Differentiation is made between DC welding and AC
welding. DC welding is often used for steel, nonferrous metals and alloys. In contrast, AC
welding is predominantly used for light metals such as aluminium. TIG pulse welding has
also been developed further. Precision metered heat input makes for good line filling and root
passes, even under constrained conditions.

19.0 References
1. http://www.igm-group.com/en/products/processes/articlearchivshow-summary-of-thewelding-processes access on 24 September 2014.
2. http://www.tech.plym.ac.uk/sme/strc201/wdefects.htm access on 22 September 2014.
3. http://draftingmanuals.tpub.com/14276/css/14276_242.htm access on 20 September
2014.
4. http://en.wikipedia.org/wiki/Gas_tungsten_arc_welding access on 24 September
2014.
5. http://en.wikipedia.org/wiki/Arc_welding access on 20 September 2014.
37

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