Mode of Metal Transfer- Gas Metal Arc Welding (GMAW)

A critical variable in Gas Metal Arc Welding (GMAW) is the Mode of Metal Transfer. The mode of
metal transfer required for a specific application can vary based on many factors, including base
metal thickness and position. The mode of metal transfer is also affected by the shielding gas and
the welding parameters used in the welding procedure.

There are four modes of metal transfer:

1. Short Circuit Transfer
2. Globular Transfer
3. Spray Transfer
4. Pulsed-Spray Transfer

The stability of the welding arc and the metallurgical changes in the electrode wire are dependent
on the mode of transfer. Welding procedures are categorized according to the mode of transfer.

SHORT CIRCUIT TRANSFER (GMAW-S)

Short circuit transfer gets its name from the welding wire actually "short circuiting" (touching) the
base metal many times per second. In the short-circuit mode, weld metal is transferred from the
electrode to the work piece only during the period when the electrode is in contact with the weld
pool. When the electrode touches the work piece, the current increases and the molten metal is
pinched off and released to the work piece. Then an arc is reestablished and the process is
repeated. While welding, this cycle can repeat itself between 20 and as much as 250 times per
second.

Welding parameters for this mode of transfer are at their lowest range. This mode of transfer is
therefore suited for applications such as thin materials. Caution should be exercised when welding
thicker materials, as the low heat input characteristic of this mode of transfer can result in fusion
problems. Commonly, 100% CO2 is used for the short-circuiting mode, and this helps with
penetration with the relatively low welding parameters. Additions of Argon to CO2 can also be
used to help control high spatter levels.

Limitations of short circuit transfer may include:

1. A relatively low deposition rate
2. High probability of lack of fusion, undercut and weld spatter unless the welder is highly skilled.
3. Most Standards have restrictions on the use of GMAW-S.

GMAW Short Circuit Steel Welding Parameters

Wire Welding
Current Voltage Deposition Rate
Diameter Feed Speed
mm in m/min ipm Amps V kg/hr lbs/hr
5.3 210 110 17 1.2 2.7
0.8 0.030
7.1 280 130 18 1.5 3.3
5.3 210 140 17 1.5 3.3
0.9 0.035
7.1 280 170 18 2.0 4.5
5.3 210 190 17 2.6 5.7
1.1 0.045
7.1 280 220 19 4.0 8.0

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 Mode of Metal Transfer- Gas Metal Arc Welding (GMAW)

GLOBULAR TRANSFER (GMAW)

In the globular mode of transfer, filler metal is transferred across the arc in large droplets. The
droplets have a diameter larger than the diameter of the filler metal. The large droplet is moved
by gravity across the arc, and moves in a non-axial manner. Although the electrode wire is
pinched off at the arc, globular transfer does not achieve a true spray transfer. Globular is a more
unstable transfer, with a less smooth weld bead appearance. Generally speaking, with the
exception of Flux cored arc welding (FCAW) with 100% CO2 or 75% Argon and 25% CO2 gases,
there are few applications where globular transfer can be of benefit.

Globular transfer can, in many cases, yield more spatter. Since spatter is waste, it is not a
desirable side effect of globular transfer. Globular transfer can also cause cold lapping or
incomplete fusion due to the large droplets splashing metal out of the puddle.

A variation of Globular transfer is a high voltage, high amperage, high wire feed speed metal
transfer, and is the result of using 100% CO2 shielding gas or 75% AR-25% CO2 with parameters
in the spray transfer range. With 100% CO2 or 75% Argon and 25% CO2 gases metal transfer
will technically always be a globular transfer.

The majority of Flux cored arc welding (FCAW) is done in the globular metal transfer mode.

Limitations of globular transfer include:

1. The presence of spatter *
2. A less desirable weld appearance than spray or pulsed spray transfers*
3. Welding limited to flat position and horizontal fillet welds only*
4. Welding limited to metal 1/8" or thicker
*with the exception of FCAW

SPRAY TRANSFER (GMAW)

In the spray mode of transfer, filler metal is transferred across the arc in a continuous, directed
stream of fine (smaller than the wire diameter) droplets. The movement of metal across the arc is
distinct from the globular mode of transfer, in that the droplets are smaller and directed, and the
arc is more stable. Also, as opposed to globular where a few drops move across the arc each
second, spray transfer involves hundreds of drops per second.

The welding parameters required for spray are higher than for globular. The parameters must be
above the "transition current", which varies based on wire diameter and shielding gas.

Because of the high voltage, wire feed speed and amperage; there is a resulting high current
density. The high current density produces high metal deposition rates. The high degree of heat
in the spray arc weld puddle makes for a larger weld puddle that is more fluid than the weld
puddle for short circuit transfer. Because of this heat and the size of the weld puddle, spray
transfer is somewhat limited in welding positions. The heat and size of the weld puddle also limits
spray transfer to material 1/8" or thicker. Welding with solid filler materials (i.e. ER70S-X,
ER308L) using spray transfer mode is usually done in the flat and the horizontal fillet weld
position. With metal-cored (i.e. E70C-6M), or flux-cored (i.e. E71T-1, E316LT-1) welding filler
materials, spray transfer can be accomplished in all positions.

To achieve a true spray transfer, an argon-rich shielding gas must be used. Usually a gas mixture
of over 80% argon is used, with the remainder being a gas that gives special metal transfer
characteristics, such as oxygen or CO2 or a combination of oxygen and CO2.

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 Mode of Metal Transfer- Gas Metal Arc Welding (GMAW)

Advantages of spray arc transfer include:

1. High deposition
2. Good fusion and penetration
3. Good bead appearance
4. Capability of using large diameter wires
5. Presence of very little (if any) spatter

Limitations of spray arc transfer include:

1. Used only on material 1/8" and thicker (hand held) *
2. Limited to flat and horizontal fillet weld position (except for some spray transfer on
aluminum)*
3. Good fit-up is always required as there is no open root capability*
*With the exception of metal-cored or flux-cored welding filler materials

Transition Current
from Short Circuit to Spray Mode
Wire Diameter Current Voltage
mm in Amps V
0.9 0.035 175-200 25
1.1 0.045 220-240 26
1.3 0.052 250-260 28
1.6 0.062 260-280 30

Typical starting GMAW parameters in Spray Mode

for selected welding conditions
Wire Metal Welding Feed Deposition
Current Voltage
Diameter Thickness Speed Rate
mm in mm in m/min ipm Amps V kg/hr lbs/hr
3 0.12 10.7 420 180-230 25-28 3.2 7
4 0.16 12.4 490 220-260 27-29 3.6 8
0.9 0.035 4.8 0.19 14.2 560 245-280 28-30 4.1 9
5.6 0.22 16 630 260-310 30-32 4.5 10
6.4 0.25 17.8 700 280-350 31-34 5 11
4.8 0.19 8.9 350 240-270 26-27 4.1 9
5.6 0.22 10.7 420 280-300 27-29 5 11
1.1 0.045 6.4 0.25 12.4 490 310-340 29-31 5.9 13
9 0.35 14.2 560 370-380 30-32 6.8 15
12 0.5 16 630 390-410 31-33 7.7 17

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 Mode of Metal Transfer- Gas Metal Arc Welding (GMAW)

Electronically Controlled Short-Arc

Electronically Controlled Short-Arc is a modified short circuit transfer MIG process (GMAW-S) that
precisely controls the power source’s current and voltage parameters digitally during all phases of
the droplet transfer. The welding equipment monitors the short circuit and controls the correct
timing of the filler droplet transmission from the filler wire into the weld pool.

Electronically controlled Short-Arc provides a more stable puddle that produces excellent side wall
fusion and tie-ins, makes it easier for the welder to produce high quality root passes on pipe and
accommodates poor fit-ups without difficulty. It is specifically designed for open-root pipe joints in
carbon steel, chrome-moly steel and stainless steel using solid and metal cored wires.

Trade names for Electronically Controlled Short-Arc include Miller Electrics’ RMD Pro and Pro-Pulse
(Regulated Metal Deposition) and Lincoln Electrics’ Power Mode or Surface Tension Transfer (STT)

Benefits of Electronically Controlled Short-Arc compared to conventional short circuit MIG

• Designed for root pass welding

• Can replace TIG in some applications
• Good gap filling; tolerant of joints with high-low sides
• Reduces spatter
• Reduces heat input
• Allows less-skilled welders to put in x-ray quality welds
• Very tolerant of changes in tip to work distance
• Excellent out-of-position puddle control
• Allows welds to fill in at toes, increasing travel speed and deposition rate

PULSED-SPRAY TRANSFER (GMAW-P)

In pulse spray transfer (GMAW-P) the welding power source’s pulse control pulses the welding
output with high peak currents (amperage) which are set at levels which will cause the transfer to
go into a spray. The background current (amperage) is set at a level that will maintain the arc,
but is too low for any metal transfer to occur.

Because there is no metal transfer during the background portion of the cycle, the weld puddle
gets a chance to freeze slightly. This is unlike a spray transfer, where drops of molten metal are
continuously transferred.

This faster-freezing weld puddle is what allows the pulsed-spray transfer to be used for thinner
metals, and for better control on out-of-position work. GMAW-P often allows for larger wire sizes
to be used on varied metal thicknesses. This is especially helpful for feeding aluminum wires
through conventional (push vs. push/pull) type gun assemblies.
Pulsed-spray transfer is often used to provide all-position welding on both light and heavy gauge
metal thicknesses.

The following table compares minimum current for spray transfer and pulsed-spray transfer.
Notice how much lower the values are for pulsed-spray transfer.

Because heat input is lower, pulsed-arc spray transfer also allows for welding thinner materials
with minimum distortion. For gauge material as well as out-of-position work, the advantages are
due to the unique metal transfer.

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 Mode of Metal Transfer- Gas Metal Arc Welding (GMAW)

Wire
Electrode Minimum
Wire Diameter Minimum Pulse
Electrode Spray Arc Spray Average
Type Shielding Gas Current Current
mm in
Mild Steel 0.89 .035 98% Argon – 2% Oxygen 165 48
Mild Steel 1.14 .045 98% Argon – 2% Oxygen 220 68
Stainless Steel 0.89 .035 99% Argon – 1% Oxygen 170 57
Stainless Steel 1.14 .045 99% Argon – 1% Oxygen 225 104
Aluminum 1.19 .047 100% Argon 135 44
Aluminum 1.59 .062 100% Argon 180 84
Silicon Bronze 0.89 .035 100% Argon 165 107
Silicon Bronze 1.14 .045 100% Argon 205 133

Double-pulse welding
A variation on Pulsed Spray Transfer is Double-pulse spray transfer. In Double-pulse spray
transfer not only is the amperage pulsed but the wire feed speed (Voltage) as well. This means
that the wire feed speed, voltage and amperage varies during welding, and the user can adjust
the amplitude* and frequency* of the variation. This allows for adjusting the desired penetration
and weld profile. It also helps control the weld pool in all welding positions. The mechanical
movement of the puddle caused by pulsing the wire feed speed and voltage also causes grain
refinement in the finished weld.

*The frequency of a double pulse refers to the number of times a double pulse is repeated in one
second, and the amplitude refers to the magnitude of the change. This affects the appearance
and heat input of the weld.

Summary
The selection of the right mode of transfer is always dependent on your specific application.
Knowing what mode you need and what mode you are in is critical whether qualifying your
welders, writing your procedures or during production welding.

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