Gas Metal Arc Welding

Dr. VISHVESH J. BADHEKA,

Associate Professor, School of
Technology,
 History

• Originally developed for welding aluminium and other

non-ferrous materials in the 1940s.

• Soon applied to steels because it allowed for lower

welding time compared to other welding processes.
 Introduction
• Also referred by subtypes,
metal inert gas (MIG) welding or
metal active gas (MAG) welding.

• Arc welding process wherein coalescence is produced by

heating the job with an electric arc established between a
continuously fed metal electrode and the job.

• Semi-automatic or automatic arc welding process

• It is utilized particularly in high production welding

operations.
• Molten pool is shielded by the inert gas envelope

• Joints are stronger, more ductile, and more corrosion

resistant

• Here solid wire has no slag, thus eliminating slag

inclusion

• Metals such as C.S.,S.S., Al, and Cu can be welded with

this process by choosing the appropriate
shielding gas
electrode and
welding conditions.
Principle of operation
 Principle of operation

• Before initiating the arc, gas and water

flow, is checked. Current, wire feed
speed is set.

• The arc is struck by 2 methods:

1) Current and shielding flow is switched on the electrode is scratched
against the job as usual practice for striking the arc.

2) Electrode is made to touch the job, is retracted and then moved

forward to carry out the welding.

• Distance at which electrode is projected from the torch before striking the
arc is 15 mm.

• During welding, torch remains about 10 -12 mm away from the job and
arc length is kept between 1.5 to 4 mm
 Metal transfer in GMAW
• Material is transferred from the tip of the consumable
electrode into the weld pool has a significant influence on
the overall performance of GMAW.

• It affects
- Process stability
- Spatter generation
- Weld quality
- Positional capabilities of process.

• In free flight transfer mode an arc is maintained between

the electrode and the workpiece and the metal is
transferred across the arc in the form of droplets.
• The common free flight modes are:

- Axial spray transfer (drop projected streaming)

- Globular transfer (drop and repelled)

- Short circuiting transfer

• Axial Spray Transfer (gas shield with a minimum of 80
percent argon)

• Metal transfer across the arc is in the form of droplets of

a size equal to or less than the electrode diameter.

• The droplets are directed axially in a straight line from

the electrode to the weld puddle. The arc is very smooth
and stable.

• The result is little spatter and a weld bead

of relatively smooth surface.

• The arc (plasma) energy is spread out in

a cone-shaped pattern.
• This results in good relatively shallow penetration
(shallow depth of fusion).

• Penetration is less than can be obtained with the high

energy globular transfer mode of GMAW.

• The axial spray transfer mode is established at a

minimum current level for any given electrode diameter
• Globular Transfer (gas shield with CO2 or helium).

• In this mode, metal transfer across the arc is in the form

of irregular globules randomly directed across the arc in
irregular fashion (See Fig.)

• Resulting in a considerable
amount of spatter.

• Spatter is minimized when using a CO2 shield by

adjusting the welding conditions so that the tip of the
electrode is below the surface of the molten weld metal.
• It presents a weld bead surface that is rough in
appearance (ripple effect) in comparison to a bead
obtained with axial spray transfer.

• Since most of the arc energy is directed downward and

below the surface of the molten weld metal, the weld
bead profile exhibits extremely deep penetration that is
less than that obtained in the axial spray transfer mode.

• Helium-rich gas mixtures are used, a broader weld bead

is produced with a penetration depth similar to that of
argon, but it is used with more desirable profile.
• Short Circuiting Transfer
• In the short circuiting, low energy mode, all metal
transfer occurs when the electrode is in contact with the
molten puddle on the work-piece

• In this mode of metal transfer, the power source

characteristics control the relationship between the
intermittent establishment of an arc and the short
circuiting of the electrode to the work.

• Heat input is low, weld bead penetration is very shallow

and care must be exercised in technique to assure good
fusion in heavy sections.

• These characteristics permit welding in all positions.

• Short circuiting transfer is particularly adaptable to

welding thin gauge sections.
 The GMAW Set-up

- torch
- electric power source
- shielding gas source
- wire spool with wire drive control
 The GMAW Set-up

Wire

Wire Feeder

Power Source

Water Cooler
(optional)
Regulator / Flow meter

Shielding Gas

Welding Gun

Work Ground Clamp

Work piece (Base

Material)
 Tools of the trade

• Power Supply
• Gas Supply

• Wire feeder
• Gun and Whip

• Process
 Power supply
• Most applications of gas metal arc welding use a CV
power supply.

• Any change in arc length (which is directly related to

voltage) results in a large change in heat input and
current.

• Shorter arc length will cause a much greater heat input,

which will make the wire electrode melt more quickly and
thereby restore the original arc length

• This helps operators keep the arc length consistent even

when manually welding with hand-held welding guns.
• Sometimes a constant current power source is used in
combination with an arc voltage-controlled wire feed unit.

• Change in arc length makes the wire feed rate adjust in

order to maintain a relatively constant arc length.

• CC power source and a constant wire feed rate unit

might be coupled, especially for the welding of metals
with high thermal conductivities, such as aluminum
 Direct Current Electrode Positive (DCEP)

• Generally used for gas metal arc welding

– Provides maximum heat input into work allowing
relatively deep penetration to take place
– Assists in removal of oxides from plate
– Low current values produce globular transfer of metal
from electrode
 Direct Current Electrode Negative (DCEN)

• Limited use in welding of thin gauge materials, Greatest

amount of heat occurs at electrode tip

• Wire melt off rate is higher than DCEP, Penetration also

less than with DCEP
 Electrode
• Electrode selection is based primarily on
- Composition of the metal being welded,
- Process variation being used,
- Joint design and the material surface conditions

• Electrode selection greatly influences the mechanical

properties of the weld and is a key factor of weld quality.

• In general the finished weld metal should have

mechanical properties similar to those of the base
material with no defects such as
- discontinuities,
- other contaminants
- porosity within the weld.
• All commercially available electrodes contain deoxidizing
metals such as silicon, manganese, titanium and
aluminum in small percentages to help prevent oxygen
porosity.

• Some contain denitriding metals such as titanium and

zirconium to avoid nitrogen porosity

• The diameters of the electrodes used in GMAW typically

range from 0.7 to 2.4 mm (0.028–0.095 in) but can be as
large as 4 mm (0.16 in).

• Smallest electrodes - 1.14 mm (0.045 inch) (short-

circuiting metal transfer process)

• While at least 0.9 mm (0.035 inch). For most common

spray-transfer process
 Welding gun and wire feed unit
• The typical GMAW welding gun has a number of key parts
- control switch
- contact tip
- power cable
- gas nozzle
- electrode conduit and liner
- gas hose

• The control switch, or trigger, when pressed by the

operator, initiates the wire feed, electric power, and the
shielding gas flow, causing an electric arc to be struck.

• Contact tip (copper) connected to the welding power

source through the power cable and transmits the
electrical energy to the electrode while directing it to the
weld area
• GMAW torch nozzle cutaway image.
(1) Torch handle,
(2) Molded phenolic dielectric (white)
threaded metal nut insert (yellow),
(3) Shielding gas diffuser,
(4) Contact tip,
(5) Nozzle output face

• The wire feed unit supplies the electrode to the work,

driving it through the conduit and on to the contact tip.

• Some wire feeders can reach feed rates as high as

30.5 m/min (1200 in/min).

• Feed rates for semiautomatic GMAW typically range

from 2 to 10 m/min (75–400 in/min).
 Shielding Gas

• Argon and helium first used for gas metal arc

– Continue to be basic gases

• Argon used more than helium on ferrous metals to keep

spatter at minimum
– Also heavier than air so good weld coverage

• Oxygen or carbon dioxide added to pure gases to

improve arc stability, minimize undercut, reduce porosity,
and improve appearance of weld
• Helium added to argon to increase penetration

• Hydrogen and nitrogen used for only limited number of

special applications

• Carbon dioxide has following advantages:

– Low cost
– High density, resulting in low flow rates
– Less burn-back problems because of its shorter arc
characteristics
 Specific Metal Recommendations
• Aluminum alloys: argon

• Magnesium and aluminum alloys: 75 percent helium, 25 percent

argon

• Stainless steels: argon plus oxygen

• Magnesium: argon

• Deoxidized copper: 75 percent helium, 25 percent argon preferred

• Low alloy steel: argon, plus 2 percent oxygen

• Mild steel: 15 percent argon, 25 percent carbon dioxide
(dip transfer); 100 percent CO2 may also be used with
deoxidized wire

• Nickel, Monel®, and Inconel®: argon

• Titanium: argon

• Silicon bronze: argon

• Aluminum bronze: argon

Penetration profiles

• Argon has a finger nail

penetration profile
consistent with spray
transfer

• CO2 and He. have

elliptical penetration
consistent with the
globular transfer
 Weld Defects

• Grain Growth
– A wide T will exist between base metal and HAZ.
– Preheating and cooling methods will affect the
brittleness of the metal in this region

• Blowholes
– Are cavities caused by gas entrapment during the
solidification of the weld puddle.
– Prevented by proper weld technique (even
temperature and speed)
• Inclusions
– Impurities or foreign substances which are forced into
the weld puddle during the welding process.
– Has the same effect as a crack. Prevented by proper
technique/cleanliness.

• Segregation
– Condition where some regions of the metal are
enriched with an alloy ingredient and others aren’t.
– Can be prevented by proper heat treatment and
cooling.

• Porosity
– The formation of tiny pinholes generated by
atmospheric contamination. Prevented by keeping a
protective shield over the molten weld puddle.
 Residual Stresses
• Rapid heating and cooling results in thermal stresses
detrimental to joint strength.

• Prevention

– Edge Preparation/Alignment – beveled edges and

space between components to allow movement

– Control of heat input

– Preheating – reduces expansion/contraction forces

(alloys) and removes moisture from the surface

– Jigs and Fixtures – prevent distortion by holding

metal fixed
 Joint Design

BUTT JOINT

FILLET JOINT

STRAP JOINT

LAP JOINT
CORNER JOINT
 Safety

Burn hazard Protection clothes and gloves

Eye protection against spatters and

Helmet or special glasses
ultraviolet and infrared rays

Toxic gases:
- carbon monoxide (CO)
Well ventilated area
- ozone (O2)
- phosgene gases produced with
some metals when welded
 Advantages
• High operating factor

• Easy to learn

• Limited cleanup

• Use on many different metals: stainless steel, mild

(carbon) steel, aluminum and more

• All position

• Great for home use with 115 V and 230 V units

 Disadvantage

• Less portable with shorter gun lengths (15 foot guns)

• GMAW equipment is more expensive than SMAW

equipment

• External shielding gas can be blown away by winds

• High radiated heat

• Difficult to use in out of position joints

 Applications
• Process can be used for the welding of carbon, Si, and
low alloy steels, S.S., Al, Mg, Cu, Ni, and their alloys, Ti
etc.

• For welding tool steels and dies.

• For the Mfg. of refrigerator parts.

• In industries like aircraft, automobile, pressure vessel,

and ship building.
 References
• Guidelines For Gas Metal Arc Welding (GMAW) - Miller
Electric Mfg. Co.

• MIG/MAG Welding Guide - published by American

Society for Metals.

• Advanced welding processes – technological and

process control – John Norrish – Woodhead publishing
limited – Cambridge, England
Thank You