WHAT IS TANDEM MIG/MAG (GMA) WELDING

In the tandem MIG/MAG process (sometimes referred to as 'twin-wire' or double wire

welding), two wires are continuously fed through a special welding torch and are
consumed to form a single molten pool. In current systems, the wires are electrically
isolated from each other within the contact tip. Systems normally comprise two separate
wire feed units and two power sources, so the wires can be operated independently i.e.
with different wire diameters, current levels or operating modes (continuous or pulsed).
In pulsed mode, the current in each wire is pulsed alternately to avoid magnetic
interactions between the two arcs. Welding commonly takes place with the two wires in
line along the joint line, although the torch can be rotated across the joint to give a wider
weld bead.

Twin-wire GMAW systems have only recently become commercially available since
1996. The process offers high deposition rates - up to 24 kg/h at a travel speed of
0.8m/min has been claimed (1) - and travel speeds more than twice that of conventional
GMAW have been reported (up to 5m/minute for a 2mm lap joint). At increased travel
speeds, heat input is reduced and less distortion occurs. It is also claimed that tandem
MIG/MAG reduces porosity because the elongated weld pool extends the degasification
time. Metal- or flux-cored wires can also be used to further increase deposition rates.

However, this technology can only be used for mechanised or robotic welding because
of the precision required in positioning the bulky torch. Joint accessibility is also
restricted because of the torch size.

The tandem MIG/MAG process has been applied in the automotive industry, and in the
shipbuilding, construction equipment, railway vehicle, and boiler construction fields for
welding aluminium alloys, steels and other materials. Weld overlays have also been
deposited using this technique.

1. Platz J: 'Two-wire technique increases the speed in MAG welding (Dvojdrotova

technika...)'. Zvaranie/Svarovani vol.45, no.6, June 1996. pp.124-126. (English
translation of text and captions pp.4-5).