Gas Metal Arc Welding

By L D Poyyara

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 What Is GMAW ?
• A Fusion Welding Process – Semi Automatic
• Arc Between Consumable Electrode &Work
• Arc Generated by Electric Energy From a Rectifier
/ Thyrester / Inverter
• Filler Metal As Electrode Continuously fed From
Layer Wound Spool.
• Filler Wire Driven to Arc By Wire Feeder through
Welding Torch
• Arc & Molten Pool Shielded by Inert Gas through
Torch / Nozzle
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 Gas Metal Arc Welding
• MIG – Shielding Gas Ar / Ar + O2 / Ar + Co2

• MAG – Shielding Gas Co2

• FCAW – Shielding Gas Co2 With Flux cored

Wire
Note:- Addition of 1 – 5% of O2 or 5 – 20% of Co2 in Ar.
increases wetting action of molten metal

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Power Source For MIG / MAG

• Inverter- DC
• Thyristor – DC
• Diesel Generator – DC
• Rectifier – DC

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Characteristic Of GMAW Power
Source
Constant V / Linier Characteristic

Appx. Horizontal
Curve
V1
V2

A1 A2
A
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 Current & Polarity

DC- Electrode +Ve

Stable Arc
Smooth Metal Transfer
Relatively Low Spatter
Good Weld Bead Characteristics
DC- Electrode – Ve, Seldom Used
AC- Commercially Not In use
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 Accessories Of GMAW
• Power Source
• Wire Feed Unit
• Shielding Gas Cylinder, Pressure gauges/
Regulator, Flow meter ( Heater For Co2 )
• Welding Torch
• Water Cooling System (For Water cooled Torch)
• Earthing Cable With Clamp

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 Tools For GMAW
• Head Screen With DIN 13 / 14 Dark Glass
• Hand Wire Brush / Grinder With Wire Wheel
• Cutting Pliers
• Hand Gloves
• Chipping Hammer / Chisel & hammer
• Spanner Set
• Cylinder Key
• Anti-spatter Spray
• Earthing Cable With Clamp
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 GMAW Torch
On / Off Switch

Shielding Gas Torch Handle

Spring Conduit

Gas Cup Nozzle Tip

Filler Wire - Electrode
Arc
Job

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 Equipment & Accessories
Pressure Regulator
Flow Meter

Shielding Gas
Heater
Solenoid (Only For
Switch Co2)
Valve
Shielding Gas
Cylinder
Welding Torch Wire Feeder
Copper Cup Wire Inside Spring Lining
Electrode / Contact Tip Wire
Wire Spool
Argon / Co2
Arc
– Shielding
Work
Power Source
With Inductance
Torch With Cable Max. 3Mtr
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 Types Of Wire Feeding In
GMAW
• Push Type
– Wire fed in to The torch by Pushing through Flexible
Conduit From A Remote Spool
• Pull Type
– Feed Rollers Mounted on The Torch Handle Pulls the
Wire From A Remote spool
• Self Contained
– Wire Feeder & The Spool On the Torch

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 Function Of Shielding Gas In
GMAW
• Prevents Air contamination of weld Pool
• Prevents Contamination During Metal
Transfer
• Increases fluidity of molten metal
• Minimizes the spatter generation
• Helps in even & uniform bead finish

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 Shielding Gases For GMAW
• MIG: Argon Or Helium
For Al, SS, CS, LAS & Non-ferrous
• MIG: Ar + 1 to 2 % O2, Wire With Add. Mn & Si
For SS, CS & LAS
• MIG: Ar + 5 to 20 % Co2 Wire With Add. Mn & Si
For SS, CS & LAS
• MAG: Co2 With Solid Wire
For CS
• FCAW: Co2 With Flux Cored Wire
For CS, LAS & SS Overlay
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 ASME Classification For CS
GMAW Wire
• SFA 5.18 : - CS Solid Wire
ER 70 S – 2, ER 70 S – 3
ER 70 S – 6, ER 70 S – 7

• SFA 5.20 :- CS Flux Cored Wire

E 71 T-1, E 71 T-2 ( Co2 Gas )
E 71 T-1M, E 71 T-2M ( Ar + Co2 Mix)

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 GMAW CS Wire
• Generally Copper Coated
– Prevents Oxidation / rusting in Storage
– Promotes Electric Conductivity in Arcing
• Available In Solid & Flux Cored
– Size in mm 0.8, 1, 1.2, 1.6, 2, 2.4, 3
• Manganese & Silicon ( Mn 1 – 2 %, Si Max 1%)
– Act As Deoxidizing Agents
– Eliminate Porosity
– Increase Wetting Of Molten Pool

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Metal Transfer In GMAW

• Short-Circuiting / Dip Transfer

• Globular Transfer

• Spray Transfer / Free Flight Mode

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 Metal Transfer In GMAW
CS Solid Wire 1.2 mm Φ
Up to 120A 120 to 250A Above230A

14 – 22V 16 – 24 V 24 – 35 V

Dip/Short Circuiting Globular Spray / Free Flight

Co2 or Ar Co2 or Ar Only Ar / Ar+O2

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 Short-Circuiting / Dip Transfer
• Wire In Contact With Molten Pool 20 to 200 times per Second
• Operates in Low Amps & Volts – Less Deposition
• Best Suitable for Out of Position Welding
• Suitable for Welding Thin Sheets
• Relatively Large opening of Root Can be Welded
• Less Distortion
• Best Suitable for Tacking in Set up
• Prone to Get Lack of Fusion in Between Beads

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 Globular Transfer

• Metal transferred in droplets of Size grater

than wire diameter
• Operates in Moderate Amps & Volts –
Better Deposition
• Common in Co2 Flux Cored and Solid Wire
• Suitable for General purpose Welding

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 Free Flight / Spray Transfer
• Metal transferred in multiples of small droplets
• 100 to 1000 Droplets per Second
• Metal Spray Axially Directed
• Electrode Tip Remains pointed
• Applicable Only With Inert Gas Shielding
– Not With Co2
• Operates in Higher Amps & Volts – Higher
Deposition Rate
• Not Suitable for Welding in Out of Position.
• Suitable for Welding Deep Grooves
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 Pulsed Spray Welding
• Power Source Provides Two different
Current Levels“Background” and “Peak”at
regular interval
• “Background” & “Peak” are above and
below the Average Current
• Best Suitable for Full Penetration Open
Root Pass Welding
• Good Control on Bead Shape and Finish
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 Synergic Pulse GMAW
• Parameters of Pulsed Current (Frequency,
Amplitude, Duration, Background Current) Related
to Wire feed Rate
• One Droplet detaches with each pulse
• An Electronic Control unit synchronizes wire feed
Rate with Pulse Parameters
• Best Suitable for Most Critical Full Penetration
Open Root Pass Welding
• Good Control on Open Root penetration, Bead
Shape and Finish
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 GMAW Process Variables
• Current
• Voltage
• Travel Speed
• Stick Out / Electrode Extension
• Electrode Inclination
• Electrode Size
• Shielding Gas & Flow Rate
• Welding Position

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 Parameter For 1.2 ф FC Wire
• Current – 200 to 240 A
• Voltage – 22-24
• Travel Speed 150 to 250 mm / min
• Stick Out / Electrode Extension – 15 to 20 mm
• Electrode Inclination – Back Hand Technique
• Shielding Gas – Co2, 6 L/Min

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 Parameter For 1.2 ф Solid Wire
• Current – 180 to 220 A
• Voltage – 20-22
• Travel Speed 150 to 200 mm / min
• Stick Out / Electrode Extension – 10 to 20 mm
• Electrode Inclination – Back Hand Technique
• Shielding Gas – Co2 – 6 L/Min

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 Results In Change Of Parameters
• Increase In Current
– More deposition, More Penetration, More BM Fusion
• Increase In Voltage
– More Weld Bead Width, Less Penetration, Less Reinforcement, Excess
Spatter
• Increase In Travel Speed
– Decrease in Penetration, Decrease in Bead Width,
• Decrease In Gas Flow rate
– Results In porosity
• Long Stick Out / Electrode Extension
– Excess Weld Deposit With Less Arc intensity, Poor Bead Finish,
Shallow Penetration

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 Common Defects In GMAW
1. Porosity 2. Spatters
3. Lack Of Fusion 4. Under Cut
5. Over Lap 6. Slag
7. Crack 8. Lack Of Penetration
9. Burn Through 10. Convex Bead
11. Unstable Arc 12. Wire Stubbing

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 Porosity

Cause
1) Less Mn & Si In Wire
2) Rusted / Unclean BM / Groove
3) Rusted wire
4) Inadequate Shielding Gas
Remedy
1) Use High Mn & Si Wire
2) Clean & warm the BM
3) Replace the Wire
4) Check & Correct Flow Rate

Porosity . .

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 Spatters
Cause Remedy
1) Low Voltage 1) Increase Voltage
2) Inadequate Inductance 2) Increase Inductance
3) Rusted BM surface 3) Clean BM surface
4) Rusted Core wire 4) Replace By Rust Free wire
5) Quality Of Gas 5) Change Over To Ar + Co2

Spatters
• ••

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 Lack Of Fusion
Cause
1) Inadequate Current
2) Inadequate Voltage
3) Wrong Polarity
4) Slow Travel Speed
5) Excessive Oxide On Joint
Remedy
1) Use Right Current
2) Use Right Voltage
3) Connect Ele. + Ve
4) Increase Travel speed
5) Clean Weld Joint

Lack Of Fusion

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 Undercut

Cause
1) Excess Voltage
2) Excess Current
3) Improper Torch angle
4) Excess Travel Speed
Remedy
1) Reduce Voltage
2) Reduce Current
3) Train & Qualify the Welder
4) Reduce Travel Speed

Under cut

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 Overlap
Cause Remedy
1) Too Long Stick Out 1) Reduce Stick Out

2) Inadequate Voltage 2) Increase the Voltage

Overlap

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 Slag
Cause
1) Inadequate Cleaning
2) Inadequate Current
3) Wrong Torch angle
4) Improper bead placement
Remedy
1) Clean each bead
2) Use Right Current
3) Train / Qualify welder
4) Train / Qualify Welder

Slag

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 Crack
Cause Remedy
1) Incorrect Wire Chemistry 1) Use Right Wire
2) Too Small Weld Bead 2) Increase wire Feed
3) Improper Preheat 3) Preheat Uniformly
4) Excessive Restrain 4) Post heating or ISR

crack

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 Lack Of Penetration*
Cause Remedy
1) Too Narrow Groove Angle 1) Widen The Groove
2) Inadequate Root opening 2) Increase Root Opening
3) Too Low Welding current 3) Increase Current
4) Wrong Torch angle 4) Train / Qualify Welder
5) Puddle Roll In Front Of Arc 5) Correct Torch Angle
6) Long Stick Out 6) Reduce Stick Out

* Applicable to SSFPW

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 Burn through*
Cause
1) Excess Current
2) Excess Root opening
3) Inadequate Root face
4) Too Low Travel Speed
5) Quality Of Gas
Remedy
1) Reduce the Current
2) Reduce root opening
3) Increase root face
4) Increase Speed
5) Use Ar + Co2

*Applicable to root pass

Burn trough

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 Convex Bead Finish
Cause
1) Low Current
2) Low Voltage
3) Low Travel Speed
4) Low Inductance
5) Too Narrow Groove
Remedy
1) Increase Current
2) Increase Voltage
3) Increase Travel Speed
4) Increase Inductance
5) Increase Groove Width

Uneven bead finish

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 Unstable arc

Cause Remedy
1) Improper Wire Feed 1) Check Wire Feeder
2) Improper Gas Flow 2) Check Flow Meter
3) Twisted Torch Conduit 3) Straighten Torch Cab

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 Wire Stubbing

Cause
1) Too Low Voltage
2) Too High Inductance
3) Excess Slope
4) Too Long Stick Out
Remedy
1) Increase Voltage
2) Reduce Inductance
3) Adjust Slope
4) Reduce Stick Out

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Important Terminology used in
Critical Welding
• Preheating
• Post Heating or Dehydrogenation
• Intermediate Stress relieving
• Inter pass Temperature
• Post Weld Heat Treatment

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 What Is Preheating?
• Heating the base metal along the weld joint to a
predetermined minimum temperature immediately
before starting the weld.
• Heating by Oxy fuel flame or electric resistant coil
• Heating from opposite side of welding wherever
possible
• Temperature to be verified by thermo chalks prior to
starting the weld

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 Why Preheating?
• Preheating eliminates possible cracking of weld and HAZ
• Applicable to
Hardenable low alloy steels of all thickness
Carbon steels of thickness above 25 mm.
Restrained welds of all thickness

• Preheating temperature vary from 75°C to 200°C

depending on hardenability of material, thickness & joint
restrain

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How does Preheating Eliminate Crack?

• Preheating promotes slow cooling of weld and

HAZ
• Slow cooling softens or prevents hardening of weld
and HAZ
• Soft material not prone to crack even in restrained
condition

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 What Is Post Heating?
• Raising the pre heating temperature of the weld joint to a
predetermined temperature range (250° C to 350° C) for
a minimum period of time (3 Hrs) before the weld cools
down to room temperature.
• Post heating performed when welding is completed or
terminated any time in between.
• Heating by Oxy fuel flame or electric resistant coil
• Heating from opposite side of welding wherever possible
• Temperature verified by thermo chalks during the period

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 Why Post Heating?
• Post heating eliminates possible delayed cracking
of weld and HAZ
• Applicable to
Thicker hardenable low alloy steels
Restrained hardenable welds of all thickness
• Post heating temperature and duration depends on
hardenability of material, thickness & joint
restrain

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 How does Post Heating Eliminate
Crack?
• SMAW introduces hydrogen in weld metal
• Entrapped hydrogen in weld metal induces
delayed cracks unless removed before cooling to
room temperature
• Retaining the weld at a higher temperature for a
longer duration allows the hydrogen to come out
of weld

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What Is Intermediate Stress Relieving?
• Heat treating a subassembly in a furnace to a
predetermined cycle immediately on completion of
critical restrained weld joint / joints without
allowing the welds to go down the pre heat
temperature. Rate of heating, Soaking temperature,
Soaking time and rate of cooling depends on
material quality and thickness
• Applicable to
Highly restrained air hardenable material

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 Why Intermediate Stress Relieving?

• Restrained welds in air hardenable steel highly

prone to crack on cooling to room temperature.

• Cracks due to entrapped hydrogen and built in stress

• Intermediate stress relieving relieves built in stresses

and entrapped hydrogen making the joint free from
crack prone
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 What Is Inter- Pass Temperature?
• The temperature of a previously layed weld bead
immediately before depositing the next bead over
it
• Temperature to be verified by thermo chalk prior
to starting next bead
• Applicable to
Stainless Steel
Carbon Steel & LAS with minimum impact

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 Why Inter Pass Temperature?
• Control on inter pass temperature avoids over
heating, there by
Refines the weld metal with fine grains
Improves the notch toughness properties
Minimize the loss of alloying elements in
welds
Reduces the distortion

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 What Is Post Weld Heat Treatment?
• Heat treating an assembly on completion of all
applicable welding, in an enclosed furnace with
controlled heating/cooling rate and soaking at a
specific temperature for a specific time.
• Rate of heating, Soaking temperature, Soaking
time and rate of cooling depends on material quality
and thickness
• Applicable to
All type of CS & LAS
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 Why Post Weld Heat Treatment?

• Welded joints retain internal stresses within the

structure
• HAZ of welds remains invariably hardened
• Post Weld Heat Treatment relieves internal stresses
and softens HAZ. This reduces the cracking
tendency of the equipment in service

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Thanks

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