Professional Documents
Culture Documents
(MIG Welding)
GMAW Unit Topics
2
Unit Objectives
3
GMAW Safety
4
GMAW Safety
GMAW Safety is supplemental
and does not replace the
information found in Arc Welding
Basics
Understand and follow all safety
precautions listed in Safety in
Welding, Cutting and Allied
Processes (ANSI Z49.1), and Arc
Welding Safety (E205)
Understand and follow all warning
labels found:
On welding equipment
With all consumable packaging IfIfyou
youever
everhave
haveaaquestion
questionabout
aboutyour
your
Within instruction manuals safety or those around you,
safety or those around you,
Read Material Safety Data Sheets PLEASE
PLEASEASK ASKYOUR
YOURINSTRUCTOR!
INSTRUCTOR!
(MSDS)
5
GMAW Safety
Fumes and Gases can be dangerous
Keep your head out of the fumes
Use enough ventilation, exhaust at the arc, or both, to keep fumes and gases
from your breathing zone and the general area
Local exhaust and mechanical ventilation can be used without reducing weld
quality
Electric Shock can kill to receive a shock your body must touch the electrode
and work or ground at the same time
Do not touch the electrode or metal parts of the electrode holder with skin or wet clothing
Keep dry insulation between your body and the metal being welded or ground
The coil of wire is electrically hot when the trigger is pulled
Arc Rays can injure eyes and skin -Choose correct filter shade (See chart below)
6
GMAW Safety
7
GMAW Principles
8
GMAW Definition
GMAW stands for Gas Metal
Arc Welding
GMAW is commonly referred
to as MIG or Metal Inert Gas
welding
During the GMAW process, a
solid metal wire is fed through
a welding gun and becomes
the filler material
Instead of a flux, a shielding
gas is used to protect the
molten puddle from the
atmosphere which results in a
weld without slag
GMAW is the most widely used arc welding process in the
United States
9
GMAW Circuit
Current flows from the power source through the gun cable,
gun, contact tip to the wire and across the arc. On the other
side of the arc, current flows through the base metal to the
work cable and back to the power source
Shielding gas flows through the gun and out the nozzle
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GMAW Components
Travel direction
Generally, drag on thin sheet
metal and push on thicker
materials
4 Shielding Gas
3
Weld Puddle
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1 - Electrode
12
2 - Arc
An electric arc
occurs in the gas
filled space between
the electrode wire
and the work piece
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3 - Weld Puddle
14
4 - Shielding Gas
GMAW welding
requires a shielding
gas to protect the
weld puddle
Shielding gas is
usually CO2, argon,
or a mixture of both
15
5 - Solidified Weld Metal
16
Application Activity
17
GMAW Components
Application Activity
2 __________
Travel direction
4 4 __________
5 __________
5 2 1
18
Equipment Set Up
19
GMAW Equipment Set Up
1. Connect work clamp
2. Select electrode
a. Type
b. Diameter
3. Select shielding gas
4. Turn power supply on
5. Adjust machine output
a. Wire feed speed
b. Voltage
6. Adjust gas flow rate
20
GMAW Process Variables
Welding variables
Wire Feed Speed (WFS)
Voltage
Operator controlled variables
Travel speed
Gun angles
Contact tip to work distance
(CTWD)
Gas flow rate
21
Striking an Arc
and Making a Weld
22
Striking an Arc
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Laying a Bead
The
Theappearance
appearanceofofthe thepuddle
puddleandand
ridge where molten metal solidifies
ridge where molten metal solidifies
indicates
indicatescorrect
correcttravel
travelspeed.
speed.TheThe
ridge should be approximately
ridge should be approximately 3/83/8
(10
(10mm)
mm)behind
behindthethewire
wireelectrode.
electrode.
Most
Mostbeginners
beginnerstend
tendtotoweld
weldtoo
toofast
fast
resulting in a ropey bead which
resulting in a ropey bead which
means
meansSLOW
SLOWdown!down!
24
Fill the Crater
25
Restarting a Bead
26
Modes of Metal
Transfer
27
Modes of Metal Transfer
GMAW is a process that
features several distinctive,
individual methods and types
of metal transfer
The mode of metal transfer is
determined by a number of
welding variables
Voltage
Amperage
Shielding Gas
By changing one or more
variables, you can go from
one metal transfer mode to
another
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Modes of Metal Transfer
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Axial Spray Arc Transfer
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Troubleshooting
Welds
32
Troubleshooting Welds
GOAL - Make Good Welds Eliminate Ropey Convex bead
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Advantages and
Limitations
34
Advantages of GMAW
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Limitations of GMAW
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AWS Classification of
GMAW Electrodes
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AWS Classification of
GMAW Electrodes
ER70S-X
Electrode
Rod
70,000 psi Min. Tensile Strength
Solid
Chemistry, Amount of Deoxidizers (Silicon,
Manganese and/or Aluminum, Zirconium and
Titanium) X=2,3,4,6,7 or G
38
Lesson Plans
39
GMAW Lesson #1
Objective: To run a stringer (straight) bead using short arc transfer and to fill the
crater
Equipment:
Single Process - Constant Voltage Power Source & Wire Feeder
Power MIG 215 or Power MIG 255C
Multi-Process
Composite: Power MIG 350 MP
Combination: V-350/ LF-72 package
Material:
Mild Steel Plate 3/16 or thicker
.035 SuperArc L-56 (ER70S-6)
100% CO2 or 25% CO2/ 75% Argon blend shielding gas
40
GMAW Lesson #2
Objective: To make a fillet weld on a lap joint in the horizontal position (AWS
position 2F)
Equipment:
Single Process - Constant Voltage Power Source & Wire Feeder
Power MIG 215 or Power MIG 255C
Multi-Process
Composite: Power MIG 350 MP
Combination: V-350/ LF-72 package
Material
Mild Steel Plate 10 gauge
.035 SuperArc L-56 (ER70S-6)
100% CO2 or 25% CO2/ 75% Argon blend shielding gas
2F
41
GMAW Lesson #3
Objective: To make a fillet weld on a tee joint in the horizontal position
(AWS position 2F)
Equipment:
Single Process - Constant Voltage Power Source & Wire Feeder
Power MIG 215 or Power MIG 255C
Multi-Process
Composite: Power MIG 350 MP
Combination: V-350/ LF-72 package
Material:
Mild Steel Plate 10 gauge
.035 SuperArc L-56 (ER70S-6)
100% CO2 or 25% CO2/ 75% Argon blend shielding gas
2F
42
GMAW Lesson #4
Objective: To make a fillet weld on a lap joint in the vertical position welding
down (AWS position 3FD)
Equipment:
Single Process - Constant Voltage Power Source & Wire Feeder
Power MIG 215 or Power MIG 255C
Multi-Process
Composite: Power MIG 350 MP
Combination: V-350/ LF-72 package
Material:
Mild Steel Plate 10 gauge
.035 SuperArc L-56 (ER70S-6)
100% CO2 or 25% CO2/ 75% Argon blend shielding gas
3FD
43
GMAW Lesson #5
Objective: To make a fillet weld on a tee joint in the vertical position welding down (AWS
position 3FD)
Equipment:
Single Process - Constant Voltage Power Source & Wire Feeder
Power MIG 215 or Power MIG 255C
Multi-Process
Composite: Power MIG 350 MP
Combination: V-350/ LF-72 package
Material:
Mild Steel Plate 10 gauge
.035 SuperArc L-56 (ER70S-6)
100% CO2 or 25% CO2/ 75% Argon blend shielding gas
3FD
44
GMAW Lesson #6
Objective: To make a butt weld with a gap in the vertical position
welding down
Equipment:
Single Process - Constant Voltage Power Source & Wire Feeder
Power MIG 215 or Power MIG 255C
Multi-Process
Composite: Power MIG 350 MP
Combination: V-350/ LF-72 package
Material:
Mild Steel Plate 10 gauge
.035 SuperArc L-56 (ER70S-6)
100% CO2 or 25% CO2/ 75% Argon blend shielding gas
3G
45
GMAW Lesson #7
Objective: To make a fillet weld on a tee joint
in the overhead position (AWS position 4F)
Equipment:
Single Process - Constant Voltage Power
Source & Wire Feeder
Power MIG 215 or Power MIG 255C
Multi-Process
Composite: Power MIG 350 MP
Combination: V-350/ LF-72 package
Material:
Mild Steel Plate 10 gauge
.035 SuperArc L-56 (ER70S-6)
100% CO2 or 25% CO2/ 75% Argon blend
shielding gas
4F
46
GMAW Lesson #8
Objective: To make a three pass fillet weld on a tee
joint in the horizontal position (AWS position 2F)
Equipment:
Single Process - Constant Voltage Power Source
& Wire Feeder
Power MIG 215 or Power MIG 255C
Multi-Process
Composite: Power MIG 350 MP
Combination: V-350/ LF-72 package
Material:
Mild Steel Plate
.035 SuperArc L-56 (ER70S-6)
100% CO2 or 25% CO2/ 75% Argon blend shielding gas
2F
47
GMAW Lesson #9
Objective: To run a horizontal fillet weld on a tee joint using axial
spray transfer (AWS position 2F)
Equipment:
Single Process - Constant Voltage Power Source
& Wire Feeder
Power MIG 225C
Multi-Process
Composite: Power MIG 350 MP
Combination: V-350/ LF-72 package Material:
Mild Steel Plate
.045 SuperArc L-56 (ER70S-6)
90% Argon/ 10% CO2 blend shielding gas
2F
48
AWS Connection
49
American Welding Society
(AWS) Connection
50
English, Math, and Science
Connection
51
National Academic Standards
Crosswalk
52