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The benefits of MCAW when compared to GMAW

Presentation · January 2022

DOI: 10.13140/RG.2.2.22320.69129

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 Your Best Welding Partner!

The benefits of MCAW when compared to GMAW

HYUNDAI WELDING

André de Albuquerque Vicente

Yeonsun Ryu
Please don't hesitate to contact us:

André de Albuquerque Vicente

andre.vicente@hyundaiwelding.com
+55 11 9 98212400

Yeonsun Ryu
ysryu@hyundaiwelding.com
+82 10-3893-3407
Agenda

• Introduction
• Introduction to Metal-Cored Arc Welding (MCAW)
• Metal transfer methods in welding
• Importance of shielding gas
• Advantages of MCAW

• Comparision of MCAW X GMAW:

• Property of SC-70A Consumable
• Classification & General Description
• Weldability
• Deposition Efficiency & Spatter
• Mechanical Properties & Chemical Composition
• Approvals
Introduction
 Introduction
Introduction to Metal-Cored Arc Welding (MCAW)

• Metal-Cored Arc Welding (MCAW) uses the heat generated by a DC electric arc to
fuse metal in the joint area. In this process, welders create an arc between the base
metal and a continuously fed consumable filler metal. A DC electric arc produces heat
that melts both the metals in its immediate vicinity, fusing them to create a weld joint.

• Here the arc is struck between a continuously fed consumable filler wire and the work
piece, melting both the filler wire and the workpiece in the immediate vicinity.

• The entire arc area is covered by a shielding gas, which protects the molten weld pool
from the atmosphere.

• MCAW is a variant of the MIG/MAG welding process. Although there are many
common features between the two processes, there are also several fundamental
differences, most notably the fact that MCAW operates over a wider range of
shielding gases and offers more flexibility with alloy compositions than solid wire MIG.
 Introduction
Metal transfer methods in welding

• There are four basic metal transfer methods in welding:

• 1. Short circuit transfer: Short circuit transfer uses a lower voltage when causing a
short circuit between the wire and the base metal. The heat produced by the short cir
cuit, melts the two metals, creating a weld pool. The second time the wire touches the
pool, the fusion begins. Processes that utilize shielding gases where the ratio of
argon is 75% to 85% use the short circuit method. Short circuit transfer produces
quite a bit of spatter, but it is still safe to use for all welds and on all thicknesses of
steel plates and sheets.

• 2. Globular transfer: In this technique, the weld metal is transferred across the arc in
large droplets. The droplets are sometimes more massive than the electrode itself.
This mode generates the most spatter, which limits its usage to only vertical and over
head welds. The Globular Transfer method is not known for producing a very smooth,
durable bead. It is typically only used on carbon steel with 100% CO2 as the shielding
gas.
 Introduction
Metal transfer methods in welding
• 3. Spray transfer: Similar to Globular Transfer, weld metal in the Spray Transfer
method travels across an arc. The droplets in this technique are minute and
resemble that of water spouting out of a hose. Spray transfer uses high voltage and
amperage to produce an arc that is on at all times. Welders use the spray transfer
method for most MCAW procedures. It produces vast weld puddles and minimal
splatter. The large weld puddle is why its application is limited for use on very thick
metals in flat or horizontal positions. It uses different combinations of shield gases
with various metals. However, in all combinations, the minimum argon level must
be 80%. Current levels in this process must be higher than the transition current. The
transition current levels vary depending on the diameter of the electrode, the shield
gas combination, and the distance from the tip to the workpiece.

• 4. Pulse-spray transfer: In this technique, a combination of low background currents

and high spray transfer current is used to transfer one drop of metal at a time. It
combines the benefits of both spray transfer and globular transfer. A lower
background current allows the weld puddle to cool down before the high transfer
current is pulsed through the metals. This method reduces the spatter produced by
the globular transfer method and gives improved sidewall fusion. It also minimizes the
weld puddle, making it suitable for use in more extensive positions.
 Introduction
Metal transfer methods in welding)

• Essentially, all four of the transfer methods mentioned above are used in GMAW
procedures. Even though in terms of technicalities, both MIG and MCAW are pretty
similar, not all of these procedures are suitable for MCAW. From the four mentioned a
bove, MCAW mostly uses either the spray transfer method or the pulsed spray
transfer method, which is also known as the dip transfer method.

• There are two common MCAW operating modes:

1. Dip transfer mode, where relatively low current and arc voltage settings cause
the electrode intermittently to short-circuit with the weld pool at a controlled
frequency;
2. Spray transfer mode, where metal is projected by an electromagnetic force
from the wire tip in the form of a continuous stream of discrete droplets
approximately the same size as the wire diameter.

• MCAW is applied mainly to welding carbon, carbon-manganese, and alloy steels,

but may also be used for welding some stainless steel grades. Like GTAW, as known
as MIG/MG welding, success hinges on the selection of the right consumables, power
source, polarity on the power source, shielding gas, and application technique.
 Introduction
Importance of shielding gas
Several factors can affect the process of selecting the right shield gas:

• Filler metal deposit rate and efficiency;

• Spatter control;

• Bead profile;

• Post weld cleaning;

• Bead penetration;

• Weld positions;

• Welding fume generations rates;

• Welding process technicalities.

 Introduction
Importance of shielding gas

• MCAW also allows you to use a wider combination of shield gases, which provides
more flexibility to the welder. Selecting the right shield gas is critical to producing a
quality weld, especially in MCAW.

• The entire arc must be covered with shielding gas. The gas will protect the weld pool
from the atmosphere, especially oxygen and nitrogen, ensuring a smooth weld. The
absence of the shielding gas can cause multiple problems in the weld.

• Using gas with higher reactivity rates like CO2 for out-of-position welds can be a
problem.

• CO2 produces weld puddles faster. Increased weld puddle fluidity makes it harder to
create a smooth weld, especially in vertical positions.

• Similarly, using a shielding gas with high reaction rates may create rapid fume
generation. When choosing a shielding gas, keep in mind the filler metal, the base
metal, and the operating parameters to minimize the production of harmful welding
fumes.
 Introduction
Importance of shielding gas

• Using a CO2 shield blend produces convex-shaped weld beads, which can lead to
over welding. Over welding can increase welding costs by 50%;

• Increased costs significantly decrease production efficiency;

• If you’re facing this problem, then you should consider changing your shield blend to
an argon-concentrated one;

• Argon allows for better bead control and produces a flat bead face that reduces the
chances of over-beading;

• Argon-based gases are less reactive as compared to CO2;

• They generate lower spatter levels when used as a shielding gas in dip transfer
mode.
 Introduction
Importance of shielding gas

• However, with argon, there is an increased risk of lack of fusion, and since it is a
colder gas, it can cool down the weld metal pretty quickly. In such situations, a blend
containing CO2 proves ideal;

• CO2 also has its disadvantages and cannot be used in pulsed or spray transfer
methods due to its high reactivity.;

• For both these methods, argon-based gases containing either oxygen or CO2 are
employed. They have lower back plasma forces, making them an ideal choice;

• Like MIG welding, success in MCAW depends upon the selection of the right
consumables, power source, polarity of the power source, shielding gas, and applicati
on technique.
Introduction
Importance of shielding gas

• The combination of the shield gas directly affects arc stability and production
efficiency in some cases.

• For the spray transfer method, in particular, shield gases with high argon rates
allow for higher productivity rates.

• Because the shield gas also directly influences the wire feed rate, choosing the
wrong gas can disrupt the entire weld procedure.

• In addition to ensuring a smooth weld, shield gases have multiple other functions
as well:

• It forms the arc plasma;

• It stabilizes the arc on the metal surface;

• It also guarantees the smooth transfer of metal droplets from the wire to the
metal pool.
 Introduction
Advantages of MCAW

• In metal cored arc welding processes, the slag levels are low as compared to solid
wire welding processes.

• The lack of slag makes welding easier, and mechanization allows for higher
productivity.

• The advantages of MCAW outweigh those of MIG, making it the better choice.

• The results show that MCAW provides better control over the finished product
provided the right combination of metals, gas, and mode of transfer is employed.
Comparision of
MCAW X GMAW
Your Best Welding Partner!

Property of SC-70A Consumable

Metal Cored Wire

HYUNDAI WELDING
Classification & General Description
■ Applications
■ Classification

Consumable Standard

AWS A 5.18 E70C-6M

SC-70A AWS A 5.36 E70T15-M21A2-CS1

EN ISO 17632-A T 46 2 M M 1 H5

■ General Description
• Building & Bridges, Structure
SC-70A is metal cored arc welding consumables for mild & 490MPa class
high tensile steel.
- Stable arc, low spatter, and minimal slag coverage in welding
- Excellent mechanical properties
- High deposition rates
- Semi-automatic and automatic applications

• Heavy Equipment
 Weldability
■ Welding Condition
Classification Contents
MCW SC-70A
Consumable (1.2mm)
Solid Wire AWS A5.18 ER70S-6

Power Source Inverter type HYUNDAI, FINE ARC II 600G

Shielding gas (Flow) 80%Ar + 20%CO2 gas (20ℓ/min) ※ T-Fillet Welding
Torch length 5m

Welding Position EN : PB (AWS : 2F)

Amp. / Volt. 280A / 30V

Welding Speed 30 cm/min

■ Weldability ■ Arc Stability

T-Fillet, Photo of weld bead SC-70A Solid Wire

Consumable
A B

A : Excellent, B : Good, C : Normal, F : Bad

SC-70A
■ Bead Appearance

SC-70A Solid Wire

Solid Wire
A B

A : Excellent, B : Good, C : Normal, F : Bad

■ SC-70A is easier to remove slag than Solid Wire.
 Deposition Efficiency & Spatter
■ Welding Condition
Stick- Welding Shielding
Amp. / Volt. Remarks
out Speed gas (Flow)
• Deposition Efficiency (%)
: Weight of Weld Metal ÷ Weight of Electrode Used * 100
Ar + • Deposition Rate (kg/hr)
30
280A/30V 20mm 20%CO2
cm/min : Wire feed speed (m/min) x 60(min/hr) / Meter of wire per Kg (m/kg)
(20ℓ/min)
• Spatter (%)
: Weight of Spatter ÷ Weight of Weld Metal * 100

■ Test Results
Deposition Effieciency (%) Deposition Rate (kg/hr) Spatter (%)

94,1 95,2 5,6

4,9
100 6,0 4,4 6
5,0 5
80 3,5
4,0 4
60
3,0 3
40
2,0 2
20 1,0 1
0 0,0 0
SC-70A Solid Wire SC-70A Solid Wire SC-70A Solid Wire
 Mechanical Properties & Chemical Composition

■ Welding Condition
Classification Contents
Welding Position PA(1G)
15
Wire Size 1.2mm

9
Layer / pass 7 / 15
20T
Interpass Temp. 150 ±15℃
Polarity DC (+)
1
Shielding gas 80%Ar + 20%CO2 (20ℓ/min)
Amp./ Volt. 280A / 30V

Mechanical properties of
Chemical composition of All-Weld Metal (Center)
All-Weld Metal (Wt. %) Impact Test
Classification Tensile Test
(Avg. Joule)

YS TS EL
C Si Mn P S Temp. Avg.
(MPa) (MPa) (%)

SC-70A 0.057 0.46 1.34 0.013 0.006 515 595 26.6 -30℃ 65

AWS A5.36
≤ 0.12 ≤ 0.90 ≤ 1.75 ≤ 0.030 ≤ 0.030 ≥ 400 490~660 ≥ 22 ≥27J at –30℃
E70T15-M21A2-CS1
 Approvals

■ SC-70A

ABS LR BV DNV-GL TUV CE DB RINA

3YSAH5 HWK-
3YSH5 SA3YH5 IIIYS H5 12079.01 42.115.05 3YSH5
300-00
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Thank you!!!
André de Albuquerque Vicente
andre.vicente@hyundaiwelding.com
+55 11 9 98212400

Yeonsun Ryu
ysryu@hyundaiwelding.com
+82 10-3893-3407