GAS METAL ARC WELDING

METAL INERT GAS

METAL ACTIVE GAS
INTRODUCTION
• GMAW uses the heat of an electric arc between a continuous bare
wire filler metal electrode and the work.
• Shielding is obtained entirely from externally supplied inert gas such as
argon or helium, an active gas such as CO2, or some combination thereof.
• GMAW can be a semiautomatic, machine, automatic, or automated
process.
• In the semiautomatic mode, the welder controls both the inclination and
distance of the welding gun from the work, and also the travel speed and
manipulation of the arc.
• Arc length and electrode feed are controlled automatically by the power
source and wire feeder controller.
PROCESS
EQUIPMENT
EQUIPMENT
EQUIPMENT
EQUIPMENT
GMA SPOT WELDING
METAL TRANSFER MODES

The gas metal arc process deposits the weld metal in the joint by
one of the following modes:

1. Spray transfer
2. Globular transfer
3. Short circuiting transfer
4. Pulsed arc transfer
METAL TRANSFER MODES
Spray Arc Metal Transfer
Spray Arc Metal Transfer

• This process is identified by the pointing of the wire tip from which very
small drops are projected axially across the arc gap to the molten weld pool.
• There are hundreds of drops per second crossing from the wire to the
base metal.
• Since the drops are separated and directed at the molten weld pool, the
process is spatter free.
• Spray transfer process requires three conditions: argon shielding (or argon-
rich shielding gas mixtures), DCEP polarity, and a current level above a critical
amount called the transition current.
Spray Arc Metal Transfer
Globular Arc Metal Transfer

• Globular transfer occurs at low currents compared to spray transfer-low,

that is, in relation to the size of the electrode.
• Low-current density at the electrode tip produces large, irregular drops of
metal that transfer to the pool without much direction.
• The result is increased amounts of spatter, as compared to spray
transfer.
• The large drops are partially supported by arc forces.
• As they become heavy enough to overcome those forces and drop into the
pool, they bridge the gap between the wire and the weld pool, producing
explosive short circuits and spatter (Figure 10-7).
Globular Arc Metal Transfer
Globular Arc Metal Transfer
Globular Arc Metal Transfer

• Carbon dioxide was one of the first gases studied during the development
of the GMAW process.
• It was abandoned temporarily because of excessive spatter and porosity in
the weld.
• After argon was accepted for shielding, further work with carbon dioxide
demonstrated that the spatter was associated with globular metal transfer.
• Additional work showed that the arc in carbon dioxide was very forceful.
• Because of this, the wire tip could be driven below the surface of the
molten weld pool.
• With the shorter arcs, the drop size is reduced, and any spatter produced
as the result of short circuits was trapped in the cavity produced by the
arc.
Globular Arc Metal Transfer

•Because carbon dioxide is an oxidizing gas, its applications to welding

carbon steels are restricted.
•It cannot be used to fabricate most nonferrous materials.
•Neither should it be used to weld stainless steels because carbon corrodes
the weld metal.
•Carbon dioxide and helium are similar in that metal transfer in both gases
is globular.
•Helium has the advantage of inertness, potentially making it useful for the
same types of applications as carbon dioxide but in nonferrous alloys.
Short-circuiting Arc Metal Transfer

•Low currents allow the liquid metal at the electrode tip to be transferred by
direct contact with the molten weld pool. A close interaction between the wire
feeder and the power supply is required. This technique is called the short-
circuiting transfer.
transfer
•Current continues to flow and the resistance causes the wire to separate
and the arc to reignite, which causes the weld to be deposited drop by drop
up to 200 drops per second.
•The short circuiting mode is a relatively cold process, and its misapplication
can result in incomplete fusion.
•It readily bridges gaps.
•Sheet metal can be welded without excessive melt-through and welds may
be made in all positions.
positions
Short-circuiting Arc Metal Transfer
The transfer mechanisms in this process are quite simple and straightforward, as
shown schematically below:
Short-circuiting Arc Metal Transfer

•If the system is properly tuned, the rate of short circuiting can reach
hundreds per second, causing a characteristic buzzing sound.
•The spatter is low and the process easy to use.
•Carbon dioxide works well with this short-circuiting process because it
produces the forceful arc needed during the arcing interval to displace the weld
pool.
•Helium can be used as well.
•Pure argon is not as effective because its arc tends to be sluggish.
•However, a mixture of 25% carbon dioxide and 75% argon produces a less
harsh arc and a flatter, more desirable weld profile. Although more costly, this
gas mixture is preferred.
Short-circuiting Arc Metal Transfer

•Small wire diameters are preferred even though more expensive.

•This process works better with a short electrode stickout.
•Although very useful for welding sheet steel, the short-circuiting process
does not produce enough heat to make quality welds in sections much thicker
than 1/4 in. (6 mm).
•Lack-of fusion defects can occur unless the process is perfectly tuned and the
welder is highly skilled.
DCRP
Pulsed-arc Metal Transfer

•Pulsed arc welding maintains a low voltage and current arc as the
background condition.
•The number of pulses per second can usually be adjusted; transfer occurs
during each pulse.
•The power supply must have pulsing capabilities.
Pulsed-arc Metal Transfer
Pulsed-arc Metal Transfer
Pulsed-arc Metal Transfer
• This technology did not receive much attention until solid-state electronics
(inverter) were developed to handle the high power required of welding
power supplies.
• Solid-state electronics provided a better, simpler, and a more economical way
to control the pulsing process.
• The newest generation of pulsed-arc systems interlocks the power supply and
wire feeder so that the proper settings of the wire feed end power supply are
obtained for any given job by adjusting a single knob.
• Such systems have been termed synergic. In some respects, these systems
are more complex because the correct interrelationships between the wire
feed speeds and power supply settings must be programmed into the
equipment, and each wire composition, wire size, and shielding gas requires a
special program.
• The manufacturer generally programs the most common combinations,
allowing space in-the computer for additional user input.
Shielding Gases

• The primary function of the shielding gas is to exclude the atmosphere from
contact with the molten weld metal.
• This is necessary because most metals, when heated to their melting point in
air, exhibit a strong tendency to form oxides and, to a lesser extent, nitrides.
• Oxygen will also react with carbon in molten steel to form carbon monoxide
and carbon dioxide.
• These varied reaction products may result in weld deficiencies, such as
trapped slag, porosity and weld metal embrittlement.
• Reaction products are easily formed in the atmosphere unless precautions are
taken to exclude nitrogen and oxygen.
Shielding Gases

In addition to providing a protective environment, the shielding gas and flow

rate also have a pronounced effect on the following:

• Arc characteristics
• Mode of metal transfer
• Penetration and weld bead profile
• Speed of welding
• Undercutting tendency
• Cleaning action
• Weld metal mechanical properties
Shielding Gases
Shielding Gases
Cleaning Action

• The cathodic cleaning action associated with argon at DCRP is very

important for fabricating metals such as aluminum,
aluminum which quickly develops
undesirable surface oxides when exposed to air.
Solid Electrode Wire

"E" denotes an electrode;

electrode
"R" denotes a rod (round) electrode.
The next two digits (three in a 5-digit number) stand for the tensile strength of
the weld deposit, times 1000.
"S" denotes a solid electrode.
The last digit is the chemical classification.
Advantages

• Can be effectively used to join or overlay many types of ferrous and

nonferrous metals.
• Gas shielding can reduce the possibility of hydrogen being introduced into the
weld zone.
• High deposition rate compared to SMAW.
• High efficiency and utilization of filler material because the continuous spool
of wire does not require changing as often as the individual electrodes used in
SMAW.
• Due to the lack of a slag coating that must be removed after welding, GMAW
is well suited for automatic and robotic welding or high production.
• GMAW is a clean process, because there is no flux present. When no slag is
present, the welder can more easily observe the action of the arc and the
weld puddle to improve control.
• Extremely versatile, wide and broad application ability.
Disadvantages

• Since GMAW uses shielding gas alone to protect the puddle from the
atmosphere excessive contamination of the base metal may cause porosity.
• Drafts or wind may disperse shielding gases, which makes GMAW
unsuitable for field welding.
• The equipment used is more complex than that used for SMAW, increasing
the possibility of mechanical problems that can lead to quality problems.
• Higher-price equipment.
• The use of short-circuiting transfer can lead to lack of fusion discontinuities.
• Inability to reach inaccessible welding areas.
• Limited distance.
• Inability to push small diameter, soft electrode through long cable.