Table 22-3 GMAW Parameters for Steel
Wire-Feed Arc
Electrode
Shielding Gas Dia. (in.)
Short Circuit Transfer
75% Ar25% CO2 0.023
CO2 (adds 12 V) 0.030
0.035
0.045
Spray Transfer
Ar + 15% O2* 0.030
0.035
0.045
1
16
*Percent of O2 needed usually depends upon metal deoxidizers and thickness of material.
poor profile. Undercut is a particular problem in making
fillet welds with current settings that are too high.
Each filler wire size and type has a minimum and
maximum current range that gives the best results. Study
Table 22-3 for comparative current ranges, as well as other
important parameters for welding carbon steel, stainless
steel, and aluminum. Note how current and wire-feed
speed are related. If the current is too high, there is the
possibility of electrode burn-back into the contact tube,
the arc is unstable, and gas shielding is disturbed. Spat-
ter results, and the deposited weld metal has poor physi-
cal characteristics. Increases in current will increase bead
height and width. As the current is increased, the voltage
must also be increased.
If the current is too low, the filler wire may become
short circuited to the work, the electrode may become red
hot, and the arc will be extinguished. If the welding can
be maintained, the arc is unstable, and poor fusion occurs.
The bead formation is high and limited to the surface of
the base metal with little or no penetration. This destroys
the advantage of gas metal arc welding, which owes its
success to the sharp concentration of high current density
at the electrode tip.
Too much or too little current affects the physical prop-
erties of the weld metal. Tensile strength and ductility
are reduced. Porosity may occur. Excessive oxides and
other impurities may be present. Bead formation is also
affected.
Travel Speed
Travel speed has a decided effect on penetration, bead
size, and appearance. It is described as the linear rate at
716 Chapter 22 Gas Metal Arc Welding Practice with Solid and Metal Core Wire: Jobs 22-J1J23 (Plate)
Amperage Speed Range Voltage
Range (in./min) Range
3090 100400 1419
40145 90340 1521
50180 80380 1622
75250 70270 1723
135230 330650 2428
165300 340625 2430
200375 225410 2432
275500 200300 2634
which the arc moves along the weld joint. In most cases
the travel speed should be sufficient to keep the welding
arc on the leading edge of the weld pool.
At a given current density, slower travel speeds provide
proportionally larger weld beads and more heat input in
the base metal per unit length of weld. The longer heating
time of the base metal increases the weld deposit per unit
length resulting in a higher and wider bead contour. If the
speed of travel is too slow, unusual weld buildup occurs.
Excessive buildup causes poor fusion, decreases penetra-
tion, porosity, inclusions, and a rough, uneven bead.
Progressively increased travel speeds have opposite ef-
fects. Less weld metal is deposited with lower heat input
per unit length of weld. This produces a narrower weld
bead and lower contour. Excessively fast speeds cause un-
dercut. The bead is irregularly shaped because there is too
little weld metal deposited per unit length of weld.
Travel speed is a variable that is as important as wire-
feed speed and arc voltage. Travel speed is influenced
by the thickness of the metal being welded, joint design,
cleanliness, joint fitup, and welding position. As travel
speed is increased, it is necessary to increase the wire-
feed speed, which in turn increases the current and the
burnoff rate, to produce the same weld cross section.
Excessive travel speed produces undercutting and a low
rate of weld metal deposit. A speed of travel that is too
slow produces overlap of the base metal, and even burn-
through on this material.
Keep in mind the arc is what is melting and penetrat-
ing into the base metal. The only place you can be assured
of getting good penetration is directly under the arc. You
cannot rely on the molten pool to achieve good fusion and
penetration. Refer to Figs. 22-14 and 22-15.
 Gun determine formation of the weld bead by affecting such
things as penetration, bead width, bead height, arc stabil-
ity, deposition rate, weld soundness, and appearance. An
understanding of these variables and their control is es-
sential if you are to master the gas metal arc process. See
Tables 22-3 through 22-5, page 718.
Electrode
Welding current and travel speed have a similar effect
on both bead height and width. Each variable increases or
Weld Pool Welding Arc decreases both bead height and width at the same time.
If travel speed is decreased, both bead height and width
Fig. 22-14 Arc must be on leading edge of weld pool to ensure are increased. Any change in these variables affects the
penetration and fusion. amount of filler metal being d eposited per a given length
of joint. Therefore, if a given travel speed and welding
current (wire-feed speed) are not providing enough weld
metal to fill a particular joint, either the travel speed must
Deep be decreased or the welding current (wire-feed speed)
must be increased.
Depth of Penetration

In multipass welding, excessive bead height interferes

with fusion between weld beads, especially along the weld
toes. This condition causes voids in the joint, which ap-
pear as wagon tracks in radiographic inspection. If the
bead width is too small, similar defects can occur due
to the undercut at the toe of the weld. This is one of the
Shallow
reasons why this text has stressed multipass beads with a
flat face.
Slow Fast
Arc voltage has the opposite effect on bead height that
Travel Speed
it has on bead width. As the arc voltage increases, bead
Fig. 22-15 There is an optimum travel speed for each situation. height decreases and bead width increases. While changes
Excessively slow or fast travel speed will reduce penetration. in travel speed and welding current (wire-feed speed)
change the overall size of the bead, changes in arc voltage
affect the shape of the bead. (Refer to Fig.22-11, p. 714.)
Summary of Operating Variables For example, if a weld bead has excessive convexity, it can
be corrected by increasing the arc voltage and thereby flat-
You will recall that the height and width of the bead ob-
tening the bead.
tained with the gas metal arc process depend on the ad-
Travel angle also affects bead contour. A trailing gun
justment and control of these variables:
angle tends to produce a high, narrow bead. The bead
Size and type of filler wire height decreases and the width increases as the trailing
Characteristics of the shielding gas angle is reduced. This effect continues into the leading
Joint preparation angle range. If the leading angle is increased too far, the
Gas flow rate bead starts to become narrow again. Refer to Table 22-2,
Voltage page 715, for a review of the effect of variable adjustments
Speed of travel on the physical characteristics of the weld bead.
Arc length
Polarity
Electrode extension
Work and travel angle
Weld Defects
Wire-feed speed (current) Each completed job requires the close and careful inspec-
tion that you have followed with all the other welding pro-
These variables are adjusted on the basis of the type of cesses presented in this text. High quality welds require
material being welded, the thickness of the material, the the application of precise welding procedures. The defects
position of welding, the deposition rate required, and the found in welds made by the gas metal arc process are sim-
final weld specifications. Proper adjustment and control ilar to those found in other welding processes. However,

Gas Metal Arc Welding Practice with Solid and Metal Core Wire: Jobs 22-J1J23 (Plate) Chapter 22 717
 Table 22-4 GMAW Parameters for Stainless Steel

Wire-Feed Arc
Electrode Amperage Speed Range Voltage
Shielding Gas Dia. (in.) Range (in./min) Range
Short Circuit Transfer
90% He + 712% Ar + 0.030 60125 150280 1623
2% CO2 0.035 75160 125280 1623
0.045 100200 110230 1624
Spray Transfer
Ar + 12% O2 0.035 180300 290600 2433
0.045 200450 250475 2435
1
16 220500 180300 2436
*Voltage slightly lower if using AR + CO2 or AR + O2.
Percent of O2 needed usually depends upon metal thickness.

Table 22-5 GMAW Parameters for Aluminum (ER4043)

Wire Arc WFS

Shielding Gas Size Voltage Amperes (in./min)
Short Circuit Transfer
Ar 0.030 1619 50120 250550
0.035 1720 65140 240425
3
64 1722 75170 160325
Spray Transfer
Ar 0.030 2027 95200 5501200
0.035 2027 110220 425850
3
64 2231 130290 250650
1
16 2232 160360 140425
3
32 2333 190450 100210
Note: Parameters may vary with wire series used. Parameters may vary for the same size and series electrode. Check
manufacturers recommendations.

the causes and the corrective action recommended are en- to secure maximum penetration into the base metal. A
tirely different. travel angle of the proper degree is required.

Incomplete Penetration Excessive Penetration

Incomplete penetration is the result of too little heat input
in the weld area. This can be corrected by increasing the
wire-feed speed and reducing the electrode extension
distance to obtain maximum current for the particular
wire-feed setting. If the wire-feed speed and stickout are
correct, check the speed of travel. It may be too fast or
too slow.
Incomplete penetration may also be caused by im-
proper welding techniques. It is important that the arc be
maintained on the leading edge of the weld pool in order
Excessive penetration usually causes excessive melt-through.
It is the result of too much heat in the weld area. This can be
corrected by reducing the wire-feed speed to obtain lower
amperage or increasing the speed of travel.
Improper joint design is another cause of excessive
penetration. If the root opening is too wide or if the root
face is too small, excessive melt-through is likely to occur.
This difficulty can be prevented before welding by check-
ing the groove angle if there is one, the root opening, and
the root face to make sure that they are correct for the

718 Chapter 22 Gas Metal Arc Welding Practice with Solid and Metal Core Wire: Jobs 22-J1J23 (Plate)
position of welding. Excessive penetration can be reme-
died during welding by increasing the electrode extension
distance as far as good working practice will allow and
weaving the gun.
Whiskers
Whiskers are short lengths of electrode wire sticking
through the weld on the root side of the joint. They are
caused by pushing the electrode wire past the leading edge
of the weld pool. Whiskers can be prevented by reducing
the travel speed, reducing the wire-feed speed, increasing
the electrode extension distance, and weaving the gun. It is
important that the welder does not allow the electrode wire
to get ahead of the weld pool.
Voids
Voids are sometimes referred to as wagon tracks because
of their resemblance in radiographs to ruts in a dirt road.
They may be continuous along both sides of the weld de-
posit. They are found in multipass welding. When the un-
derneath pass has a bead with a large contour or a bead
with too much convexity or undercut, the next bead may
not completely fill the void between the previous pass and
the plate. Voids may be prevented by making sure that the
edges of all passes are filled in so that undercut cannot
take place. Excess convexity can be reduced by welding
the next pass with a slightly higher arc voltage. Voids can
also be corrected by increasing the travel speed on the
next pass and making sure that the arc melts the previous
bead and fuses into the sides of the joint.
Incomplete Fusion
Incomplete fusion, is largely the result of improper gun
handling, low heat, and improper speed of travel. It is im-
portant that the arc be directed at the base metal and the
leading edge of the pool.
To prevent this defect, give careful consideration to the
following:
Direct the arc so that it covers all areas of the joint.
The arc, not the pool, should do the fusing.
Keep the electrode at the leading edge of the pool.
Reduce the size of the pool as necessary by adjusting
the travel speed.
Check current values carefully. Keep a short electrode
extension.
Porosity
The most common defect in welds produced by any weld-
ing process is porosity. Porosity that exists on the face of
the weld is readily detected, but porosity in the weld metal
below the surface must be determined by radiograph
Gas Metal Arc Welding Practice with Solid and Metal Core Wire: Jobs 22-J1J23 (Plate) Chapter 22 719
ultrasonic or other testing methods. The causes of most
porosity are contamination by the atmosphere, a change
in the physical qualities of the filler wire, and improper
welding technique. Porosity is also caused by entrapment
of the gas evolved during weld metal solidification. The
intense heat of the arc separates water vapor and other
hydrogen-bearing compounds from the metal. Because
these compounds are lighter than molten metal, they tend
to rise to the surface as gas bubbles before solidification.
If they do not reach the surface, they will be entrapped as
internal porosity. If they reach the surface, they appear as
external porosity. Study the following causes of porosity
carefully:
Travel is so fast that part or all of the shielding gas is
lost, and atmospheric contamination occurs.
The shielding gas flow rate is too low so that the gas
does not fully displace all the air in the arc area.
The shielding gas flow rate is too high. This draws
the air into the arc area and causes turbulence, which
reduces the effectiveness of the shield.
The shielding gases must be of the right type for the
metal being welded. The gases must be pure and dry.
The gas shield may be blown away by wind or drafts.
The welder should protect the weld area with a wind
break or the position of his or her body. In some cases
increasing the gas flow rate may be helpful when
welding outdoors.
There may be defects in the gas system. This could be
the result of spatter clogging the nozzle, a broken gas
line, defective fittings in the gas system, a defective
gas valve, or a frozen regulator. It is important that the
filler wire is in the center of the shielding gas flow. If
the wire is off center, it can produce an erratic arc that
can cause porosity.
Excessive voltage for the arc required can cause the
loss of its deoxidizers and alloying elements. This not
only causes porosity, but it also seriously affects the
physical characteristics of the weld.
J OB T IP
Job Planning
When getting yourself ready to look for
work, ask yourself:
1. What do I expect out of this job?
2. Do I plan on continuing my education?
3. In 5 years, what do I want to be doing?
 Foreign material such as oil, dirt, rust, grease, and
paint is on the wire or material to be welded. Elec-
trode wire should be stored in clean, dry areas. The
material to be welded may be cleaned with chemicals,
sandblasted, brushed, or scraped.
Improper welding techniques are used. Excessive
electrode extension coupled with an improper work
and travel gun angles and movement is a serious cause
of porosity. Removal of the gun and the shielding
gas before the weld pool has solidified causes crater
porosity and cracks. The gun should be held at its nor-
mal position at the end of the weld until the wire feed
and the flow stop. Travel speed should not be so fast
that the molten metal does not solidify under the gas
shield.
Other Defects
Warpage Warpage occurs when the forces of expansion
and contraction are poorly controlled. A thorough un-
derstanding of these forces and their relationship to each
other will enable you to reduce warpage in a weldment to
a minimum.
Weld Cracking Weld cracking is brought about by com-
positional problems, poor joint design, and poor welding
technique. The manganese content of the filler metal may
be too low, or the sulfur content may be too high. The
weld bead may be too small to withstand expansion and
contraction movements in a joint, or the speed of travel
may be too fast. Cracking can be prevented by making
sure that the filler metal has a composition suitable for the
base metal and by providing for expansion and contrac-
tion forces during welding.
GMAW electrodes may have additional deoxidizers
added to assist when using high CO2 percentage shield-
ing gases. If high argon percentage shielding gases are
substituted with these triple deoxidized electrodes, the
deoxidizers will build up in the weld metal on multipass
welding. This buildup may reduce ductility, impact prop-
erties, and make the weld metal prone to cracking.
Spatter Spatter is made up of very fine particles of metal
on the plate surface adjoining the weld area. It is usually
caused by high current, a long arc, an irregular and un-
stable arc, improper shielding gas, improper gun angles,
electrode extension, or a clogged nozzle.
Irregular Weld Shape Irregular welds include those that
are too wide or too narrow, those that have an excessively
convex or concave surface, and those that have coarse,
irregular ripples. Such characteristics may be caused
by poor gun manipulation as in correct work and travel
720 Chapter 22 Gas Metal Arc Welding Practice with Solid and Metal Core Wire: Jobs 22-J1J23 (Plate)
angles, a speed of travel that is too fast or too slow, current
that is too high or too low, improper arc voltage, improper
electrode extension, or improper shielding gas.
Undercutting
Undercutting is a cutting away of the base material along
the toes of the weld. It may be present in the cover pass weld
bead or in multipass welding. This condition is usually the
result of high voltage, excessive travel speed, wrong wire
location, wrong work angle, wrong travel angle, poor gun
technique, improper gas shielding, or the wrong filler wire.
To correct undercutting after proper settings are ensured,
move the welding gun from side to side in the joint, and
hesitate at each side before returning to the opposite side.
Producing High Quality Welds
You are urged to study the material concerning weld de-
fects carefully and to be ready to recognize poor welding
when you see it. You must take great care and have pride
of workmanship to produce quality welds. The gas metal
arc process is able to produce high quality welds in a wide
variety of materials. Make sure that you understand the
interrelationships of all the variables and that you apply
this knowledge with the manual skill of precise gun tech-
nique. Study the characteristics of these defects and their
correction.
Safe Practices
In any industrial activity, safety is a most important con-
sideration to both the worker and the employer. If workers
wish to enjoy long and profitable careers, they must have
a concern for their own health and well-being. Accidents
and a disregard of the basic safeguards for good health cut
short thousands of careers each year. Disability resulting
from accidents and poor health costs the employer thou-
sands of dollars in compensation and increased insurance
costs. In these times of serious skill shortages, the loss to
the workforce is also costly to the nation.
Welding is no more dangerous than other industrial op-
erations. The safety precautions and protective equipment
required for the MIG/MAG process are essentially the
same as for any other electric welding process. There are a
few factors, however, that need attention. You are urged to
review the general precautions contained in Chapter 32 in
addition to observing the specific precautions listed here.
Eye, Face, and Body Protection
The welding helmets and protective clothing worn when
working with the other electric welding processes are nec-
essary. The radiant energy, particularly in the ultraviolet
range, that is produced by the gas-shielded process, is
5 to 30 times more intense than that produced by shielded
metal arc welding. The lowest intensities are produced by
the gas tungsten arc; the highest, by the gas metal arc.
Argon produces greater intensities than helium does. Ra-
diant energy is particularly dangerous to the bare skin
and unprotected eyes. The greater intensity of ultraviolet
radiation also causes rapid disintegration of cotton cloth-
ing. There is, however, less spatter from hot metal and
slag, and there is less danger of clothing fires than with
shielded metal arc welding. The following clothing regu-
lations should be enforced during practice:
Standard arc welding helmets with lenses ranging in
shade from no. 6 for work using up to 30 amperes to
no. 14 for work using more than 400 amperes should
be worn. A glass that is too dark should be avoided to
prevent eyestrain. When welding in a shop or a dark
area, a lighter shade lens should be used than is nor-
mally used for welding outdoors. The arc should never
be viewed with the naked eye when standing closer
than 20 feet. The intensity at 2 feet away from the
arc is high enough to burn the eyes in a few seconds.
Good safety practice also requires that safety glasses
be worn under the welding helmet. If these have a
light tint, they protect the welder from getting a flash
from the work of other welders working in the same
area.
The skin should be covered completely to prevent
burns and other damage from ultraviolet light. The
skin can be burned if exposed to the arc for a few
minutes at a distance of 2 feet from the arc. The
back of the head and neck should be protected from
radiation reflected from bright surfaces such as alu-
minum. Gloves should always be worn, and when
welding in all positions, special leather jackets are
appropriate.
Shirts should be dark in color to reduce reflections,
thereby preventing ultraviolet burns to the face and
neck underneath the helmet. The shirt should have
a tight collar and long sleeves. Leather, wool, and
aluminum-coated cloth withstand the action of radiant
energy reasonably well.
Handling of Gas Cylinders
The shielding gases are provided in steel cylinders. The
same general precautions should be observed in the han-
dling of these cylinders as those containing oxygen and
acetylene. (Refer to Chapters 8 and 32.)
Stored cylinders should be in a protected area away
from fire, cold, and grease and away from the general
shop activity.
Gas Metal Arc Welding Practice with Solid and Metal Core Wire: Jobs 22-J1J23 (Plate) Chapter 22 721
Cylinders must be secured to equipment to prevent
their being knocked over.
The proper regulators and flowmeters must be used
with each special type of cylinder. High pressure cyl-
inders must be treated with extreme care.
Cylinders should not be dropped, used as rollers,
lifted with magnets, connected into an electric circuit,
or handled in any other way that might damage the
cylinder or regulator. When cylinders are empty, they
should be stored in an upright position with the valve
closed.
Ventilation
The ventilation requirements for shielded metal arc weld-
ing are ample for gas metal arc welding.
Ozone is generated in small quantities, generally
below the allowable limits of concentration. Adequate
ventilation ensures complete safety.
Nitrogen dioxide is also present around the area of
the arc in quantities below allowable limits. The only
point where high concentrations may be found is in
the fumes 6 inches from the arc. With only natural
ventilation, this concentration is reduced quickly to
safe levels. Special ventilation should be provided
during the MIG/MAG cutting of stainless steel and
when using nitrogen as a shielding gas.
Carbon dioxide shielding may create a hazard from car-
bon monoxide and carbon dioxide if the welders head
is in the path of the fumes or if welding is done in a
confined space. In these conditions, special ventilation
to control carbon dioxide fumes should be provided.
Eye, nose, and throat irritation can be produced when
welding near such degreasers as carbon tetrachlo-
ride, trichlorethylene, and perchloroethylene. These
degreasers break down into phosgene under the action
of the powerful rays from the arc. It is necessary to lo-
cate degreasing operations far away from the welding
activities to remove this hazard.
During welding, certain metals emit toxic fumes that
may cause respiratory irritation and stomach upset.
The most common toxic metal vapors are those given
off by the welding of lead, cadmium, copper, zinc,
and beryllium. These fumes can be controlled by gen-
eral ventilation, local exhaust ventilation, or respira-
tory protective equipment.
Much of the welding smoke and fumes can be engi-
neered out of the GMAW arc by use of a higher argon
percent (over 80 percent) and the pulse-spray mode of
transfer.
Welding guns can be purchased with a smoke extrac-
tor capability.
Electrical Safety
The electrical hazard associated with gas metal arc weld-
ing is less than that with the shielded metal arc process
because the open circuit voltage is considerably less. In
some types of equipment, however, a 115-volt control cir-
cuit may be utilized in the welding gun. This is no differ-
ent from the voltage present in many other hand tools, and
ordinary precaution ensures safety.
Electrical maintenance of the power source and wire
feeder should be done only by a qualified person. The equip-
ment should never be worked on in the electrical hot con-
dition. Routine maintenance such as gun cleaning, blowing
out the cable assembly, and alignment of the cable assembly
to the wire feeder, can be handled by the welder. Properly
maintained welding equipment is safe welding equipment.
Wire-Feeder Safety
When aligning and adjusting drive rolls, make sure the
power is turned off. Avoid pinch points when working near
drive rolls. When adjusting tension, make sure guards are
in place so that accidental contact with moving parts is
minimized. When feeding wire, keep in mind the force
being applied to the wire is sufficient to push it through
your hand or other body parts. Never let the exposed wire
come in contact with or be pointed at your body. The wire
is sharp and/or may be hot, and you can get punctured or
burned by being careless.
Fire Safety
Here again, some of the same hazards are present in gas
metal arc welding that are encountered in other welding
processes. There is less spatter, and the spatter that does
occur is smaller and does not travel as far away from the
arc zone as in shielded metal arc welding. Good practice,
however, dictates certain precautions.
Welding should not be done near areas where flam-
mable materials or explosive fumes are present.
Paint spray or dipping operations should not be lo-
cated close to any welding operation.
Combustible material should not be used for floors,
walls, welding tables, or in the immediate vicinity of
the welding operation.
When welding on containers that have previously
contained combustible materials, special precautions
should be taken.
Use a hot work permit as required.
Care and Use of Equipment
The efficient operation of welding equipment depends
on its proper application and care. Although gas metal
arc equipment is somewhat similar to that used for
722 Chapter 22 Gas Metal Arc Welding Practice with Solid and Metal Core Wire: Jobs 22-J1J23 (Plate)
manual shielded metal arc welding, there are some major
differences.
Do not push the gun into the arc like an electrode. If
you do, you will melt off the nozzle tip or contact tube.
The wire feeder pushes the wire into the arcsit back and
let the machine do the work. All you have to do is lead it
down the joint. You may proceed straight down the seam,
or you may weave the arc back and forth as you would do
with a stick electrode. Fill craters at the end of the weld
just as you always have.
Either a push or drag travel angle can be used. Push
arc technique, lends itself to tracking joints accurately at
fast travel speeds. Under the same set of conditions, push
technique produces a flatter bead shape than a drag tech-
nique, Fig. 22-16.
A drag technique lends itself to producing high beads
and fillets. The arc force holds the molten metal back
from the crater.
Whenever possible, welding should be done in the flat
welding position to take advantage of the increased pen-
etration and deposition rate that are characteristic of the
MIG/MAG process. This is especially true of large fillets
and large grooves.
Small fillets and groove welds should be positioned
so that the arc can run slightly downhill. Travel speed is
faster, and a flat-to-concave bead contour is produced. An
angle of 5 to 15 is sufficient. Sheet metal that is 14 gauge
and under can be welded vertical down.
The equipment has to be kept clean, in proper ad-
justment, and in good mechanical condition. The wire-
feeding system requires special attention. Maladjustment
leads to erratic wire feeding which in turn causes porosity.
Care of Nozzles
Keep the gun nozzle, contact tube, and wire-feeding sys-
tem clean to eliminate wire-feeding stoppages. The nozzle
Direction of Travel
Weld Weld
Metal Metal
Drag or Trailing Push or Leading
Arc Technique Arc Technique
Fig. 22-16 Both the drag and push methods are used in semi-
automatic welding. The drag, or trailing arc, produces large wide
beads; the push or leading arc, produces a flatter bead shape.