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TRAINING
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GAS METAL ARC WELDING

INTRODUCTION:
Gas Metal Arc Welding is defined as arc welding using a continuously fed consumable
electrode and a shielding gas through a welding gun. Gas Metal Arc Welding (GMAW) is the
current technology approved by the American Welding Society.
GMAW is also known as MIG or MAG Welding.
COMPARISION OF MIG & MAG
MIG: The term MIG for Metal Inert Gas, which corresponds to these processes, which
uses and inert shielding Gas. (Argon, Helium etc.,)
MAG: The term MAG, for Metal Active Gas is applied to these processes, where the
shielding as is or contains a gas. This gives rise to significant chemical reaction, which affects
the welding process. (Eg; Carbon dioxide, oxygen)
GMAW APPLICATIONS

For Welding of carbon steel

Low alloy Steel

Stainless steel

Aluminum and its alloys

Magnesium, copper, and its alloys

Nickel and their alloys ,Titanium etc.,

Tool steels and dies

Aircraft, Automobiles

Pressure vessels, ship building etc.,
PRINCIPLE
The MIG/MAG Welding is an arc welding process. In this process the source of heat is a
formed between a consumable metal electrode and work piece. The entire arc area is protected
from atmospheric contamination by an externally supplied shielding gas. The metallic electrode
provides the arc as well as filler metal. This process is also called Gas Metal arc welding.

MIG/MAG WELDING BASICS

MIG/MAG welding is operated in semiautomatic, machine, and automatic modes. It is
utilized particularly in high production welding operations.
All commercially important metals such as carbon steel, stainless steel, aluminum, and
copper can be welded with this process in all positions by choosing the appropriate shielding gas,
electrode, and welding conditions.
Practically all GMAW is done using DCEP (Electrode positive). This polarity provides
deep penetration, a stable arc and low spatter levels. A small amount of GMAW welding is done
with DCEN and although the melting rate of the electrode is high, the arc is erratic. Alternating
current is not used for gas metal arc welding.
ADVANTAGES:
1. The major advantage of gas metal-arc welding is that high quality welds can be
produced much faster than with SMAW or TIG welding.
2. MIG/MAG Welding overcomes the restriction of limited electrodes length
encountered with Manual metal arc welding.
3. As the diameter of the wire is small, the welding current density is high and thus the
deposition rate is big. Higher Arc travel speed (1m/min)
4. Good concentration of the arc realizes deep penetration.
5. The deposition efficiency is high and formation of slag is little, which makes it
unnecessary to remove slag after each pass.
6. The gas shield protects the arc so that there is very little loss of alloying elements as
the metal transfers across the arc. Only minor weld spatter is produced, and it is easily
removed.
7. Produces neat, clean and spatter free welding. Welding cost and making the process
to be more economical.
8. Hydrogen in the weld metal is low, which contributes to good crack resistance and
mechanical properties.
9. This process is versatile and can be used with a wide variety of metals and alloys,
including aluminum, copper, magnesium, nickel, and many of their alloys, as well as
iron and most of its alloys.

10. The process can be operated in several ways, including semi- and fully automatic.
MIG/MAG welding is widely used by many industries for welding a broad variety of
materials, parts, and structures.
11. Thin and thick sections can be welded effectively. Can be easily mechanized.
12. The arc and weld pool is visible, which aids correct placement of weld.

13. Allows welding in all positions.

14. Minimum quantity of smoke and fumes provides better work atmosphere.
15. Large gap can be bridged easily because of high deposition rate.
16. Distortion is less due to less number of passes and high welding speeds.
SPECIAL FEATURES
Special features of MIG/MAG Welding are:
High current density
Self adjusting arc
Different modes of metal transfer
Gas mixtures can be used
High welding speed
May be automated.

GMAW is commonly used in industries such as the automobile industry, where it is

preferred for its versatility and speed.
A related MIG/MAG process, flux cored arc welding, often does not utilize a shielding
gas, instead employing a hollow electrode wire that is filled with flux on the inside.
DISADVANTAGES
1.
2.
3.
4.
5.

The major disadvantage of this process is that it cannot be used in the vertical or overhead
welding positions due to the high heat input and the fluidity of the weld puddle.
Not Suitable for outdoor welding. Wind break screen is needed against high wind at a
velocity of 2m/sec. or higher.
Even if a long conduit cable is used, welders movable area is limited.
The price of the power source is high.
The equipment is complex compared to equipment used for the shielded metal-arc welding
process.

EQUIPMENT
The equipment used for gas metal arc welding is more complicated than that required for
shielded metal arc welding. Initial cost is relatively high, but the cost is rapidly amortized due to
the savings in labor and overhead achieved by the rapid weld metal deposition.
The equipment necessary for gas metal arc welding is listed below:
1) Power source
2) Wire feeder
3) Welding gun
4) Shielding gas supply
5) Solid electrode wire
6) Protective equipment
Gas metal arc welding equipment consists of a welding gun, a power supply, a shielding
gas supply, and a wire-drive system which pulls the wire electrode from a spool and pushes it
through a welding gun.

The Welding gun equipped with the channels for the following:

Wire feed,

Welding current

Shielding gas

Control of welding operation

Water circulation ( for water control torch)

In passing through the gun, the wire becomes energized by contact with a copper contact
tube, which transfers current from a power source to the arc.
WELDING CONTROL & WIRE FEED MOTOR

Welding control & Wire feed motor are combined into one unit

Main function is to pull the wire from the spool and feed it to the arc

Controls wire feed speed and regulates the starting and stopping of wire feed

Wire feed speed controls Amperage

WELDING GUN (TORCH)

A typical GMAW welding gun has a number of key parts a control switch, a
contact tip, a power cable, a gas nozzle, an electrode conduit and liner, and a gas hose. The
control switch or trigger, when pressed by the operator, initiate the wire feed, electric power and
the shielding gas flow.
The contact tip is normally made of copper and sometimes chemically treated to
reduce spatter. It is connected to the welding power source through the power cable and
transmits the electrical energy to the electrode. The wire is protected and guided by the electrode
conduit and liner, which help prevent buckling and maintain an uninterrupted wire feed.
The gas nozzle directs the shielding gas evenly in to the welding zone. Larger
nozzles provide grater shielding flow. It is useful for high current welding operations that
develop a larger molten weld pool. A gas hose supplies the gas to the nozzle.
Guns are available for semi-automatic operation and for automatic operation, where they
are fixed in the automatic welding head. Semiautomatic MIG welding is often referred to as
manual welding.
PARTS OF THE WELDING GUN
The gun assembly consists of the following:
Current cable
Shielding gas hose
Self lined conduit for wire feed (Spring liner)
Contact tip
Nozzle

Contact tip: Current is applied to the wire as it passes through hallow copper tube called
contact tip. The contact tip must have correct bore size for wire diameter in use.
Gas Nozzle: A copper alloy shielding gas nozzle that delivers the gas to the arc area in a non
turbulent, angular pattern to prevent aspiration of air. Gas nozzle can ranges from 10 mm to 30
mm. it is necessary to provide electrical insulation between the nozzle and the gun to avoid
accidental arcing when the nozzle touches the work. The nozzle should always be cleaned at the
end of the run. The nozzles are usually threaded to make replacement easier.
The nozzle and contact tip are particularly prone to spatter pick up, from the welding
process. Spraying with silicon oil can reduce the striking of spatter particles to the nozzle
which is chromium plated nozzle.
Maintenance: For better keeping of the welding gun the following preventive steps to be taken:
Clean the inlet and outlet guides for every spool change
Air blow and clean the wire feed liner for every spool change
Use Nozzle spray or nozzle cream for the protection of the nozzle and contact tip
from spatter at every one hour interval.
Change wire feed liner at the inlet guide for every ten spools
TYPES OF TORCHES
There are mainly three types of torches (rates as duty 300 Amps, medium 400 Amps, and
heavy 600 A
1. Straight (Robot welding)
2. Straight or goose neck torch (90 for automatic welding)
3. Swan neck (60 for semi automatic welding)

SEMIAUTOMATIC MIG WELDING GUNS

Semiautomatic, hand-held guns are usually similar to a pistol in shape. Sometimes they
are shaped similar to an oxyacetylene torch, with electrode wire fed through the barrel or handle.
In some versions of the pistol design, where the most cooling is necessary, water is directed
through passages in the gun to cool both the contact tube and the metal shielding gas nozzle.
The curved gun uses a curved current-carrying body at the front end, through which the
shielding gas is brought to the nozzle. This type of gun is designed for small diameter wires and
is flexible and maneuverable.
It is suited for welding in tight, hard to reach corners and other confined places. Guns are
equipped with metal nozzles of various internal diameters to ensure adequate gas shielding. The
orifice usually varies from approximately 3/8 to 7/8 in. (10 to 22 mm), depending upon welding
requirements.
The conventional pistol type holder is also used for arc spot welding applications where
filler metal is required. The heavy nozzle of the holder is slotted to exhaust the gases away from
the spot. The pistol grip handle permits easy manual loading of the holder against the work. The
welding control is designed to regulate the flow of cooling water and the supply of shielding gas.
It is also designed to prevent the wire freezing to the weld by timing the weld over a
preset interval.

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AIR COOLED GUNS

Air-cooled guns are available for applications where water is not readily obtainable as a
cooling medium. These guns are available for service up to 600 amperes, intermittent duty, with
carbon dioxide shielding gas. However, they are usually limited to 200 amperes with argon or
helium shielding. The holder is generally pistol-like and its operation is similar to the watercooled type. Three general types of air-cooled guns are available.
1. A gun that has the electrode wire fed to it through a flexible conduit from a remote wire
feeding mechanism. The conduit is generally in the 12 ft (3.7 m) length range due to the wire
feeding limitations of a push-type system. Steel wires of 7/20 to 15/16 in. (8.9 to 23.8 mm)
diameter and aluminum wires of 3/64 to 1/8 in. (1.19 to 3.18 mm) diameter can be fed with this
arrangement.
2. A gun that has a self-contained wire feed mechanism and electrode wire supply. The wire
supply is generally in the form of a 4 in. (102 mm) diameter, 1 to 2-1/2 lb (0.45 to 1.1 kg) spool.
This type of gun employs a pull-type wire feed system, and it is not limited by a 12 ft (3.7 m)
flexible conduit. Wire diameters of 3/10 to 15/32 in. (7.6 to 11.9 mm) are normally used with
this type of gun.
3. A pull-type gun that has the electrode wire fed to it through a flexible conduit from a remote
spool. This incorporates a self-contained wire feeding mechanism. It can also be used in a pushpull type feeding system. The system permits the use of flexible conduits in lengths up to 50 ft
(15 m) or more from the remote wire feeder. Aluminum and steel electrodes with diameters of
3/10 to 5/8 in. (7.6 to 15.9 mm) can be used with these types of feed mechanisms.
WATER-COOLED GUNS
Water-cooled guns for manual MIG welding similar to gas-cooled types with the addition
of water cooling ducts. The ducts circulate water around the contact tube and the gas nozzle.

11

Water cooling permits the gun to operate continuously at rated capacity and at lower
temperatures. Water-coded guns are used for applications requiring 200 to 750 amperes. The
water in and out lines to the gun add weight and reduce maneuverability of the gun for welding.
AIR vs. WATER COOLED WELDING GUNS
The selection of air- or water-cooled guns is based on the type of shielding gas, welding
current range, materials, weld joint design, and existing shop practice. Air-cooled guns are
heavier than water-cooled guns of the same welding current capacity. However, air-cooled guns
are easier to manipulate to weld out-of-position and in confined areas.
As compared with shielded metal arc welding, CO2 arc welding has the following
advantages and disadvantages.

POWER SOURCE AND POLARITY

The vast majority of MIG/MAG welding applications require the use of direct current
reverse polarity (electrode positive). This type of electrical connection yields a stable arc, smooth
metal transfer, relatively low spatter loss, and good weld bead characteristics for the entire range
of welding currents used.
Direct current straight polarity (electrode negative) is seldom used, since the arc can
become unstable and erratic even though the electrode melting rate is higher than that achieved
with DCRP (electrode positive). When employed, DCSP (electrode negative) is used in
conjunction with a "buried" arc or short circuiting metal transfer. Penetration is lower with
straight polarity than with reverse polarity direct current.
Alternating current has found no commercial acceptance with the MIG welding process
for two reasons: the arc is extinguished during each half cycle as the current reduces to zero, and
it may not reignite if the cathode cools sufficiently; and rectification of the reverse polarity cycle
promotes the erratic arc operation.
NECESSITY
To bring down the line voltage and increase the line current suitable to welding.
Able to get higher voltage (OCV) to initiate the arc and reduced voltage to
maintain the arc.
To maintain the arc length constantly by increasing or decreasing the burn on rate
by establishing a relation between voltage and current
Able to weld, thin section and thick section in all position, all gauges of electrode
and ferrous and non ferrous metals.

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TYPES OF POWER SOURCE

Two types of power sources are used for MIG/MAG welding: constant current and
constant voltage.
(a) Constant current power supply:
With this type, the welding current is established by the appropriate setting on the power
supply. Arc length (voltage) is controlled by the automatic adjustment of the electrode feed rate.
This type of welding is best suited to large diameter electrodes and machine or automatic
welding, where very rapid change of electrode feed rate is not required.
Constant current power sources are not normally selected for MIG welding because of the
control needed for electrode feed speed. The systems are not self-regulating.
(b) Constant voltage power supply
The arc voltage is established by setting the output voltage on the power supply. The
power source will supply the necessary amperage to melt the welding electrode at the rate
required to maintain the present voltage or relative arc length.
The speed of the electrode drive is used to control the average welding current. This
characteristic is generally preferred for the welding of all metals.
Motor Generator or DC rectifier power sources of either type may be used. With a pulsed
direct current power supply, the power source pulses the DC output from a low background
value to a high peak value. Because the average power is lower, pulsed welding current can be
used to weld thinner sections than those that are practical with steady DC spray transfer.
The inverters are included in the static category. The polarity to be used DCRP to
get the following good results:
Contribute better relation between voltage and current
Deeper penetration
Excellent cleaning action (due to electron emission from the base metal)
The output voltage is ranging from 14 50V and ranges of current according to the
output of the unit (140 600 Amps)
In CO2 welding the heat is generated by the flow of current through the gap between tip
of the electrode and the work. The voltage between the work and electrode varies with the arc
length.

13

To produce uniform weld, the welding voltage and the arc length must be maintained
constant and the rate of wire speed must be exactly balanced by the burn off rate. This
accomplished by melting the wire at the same rate it is fed in to the weld zone.
Additional advancements in equipment technology have introduced many new
models. Inverters, as well as microprocessor controls, have created the greatest attention. In
addition, multipurpose machines have provided the user with greater flexibility with a variety of
capabilities.
WIRE FEEDER
Welding power sources designed for gas metal arc welding have a 115 volt outlet to
provide power to operate the wire feeder. The wire feed unit is an important link between the
power source and the welding gun. This houses the control circuit and provides controlled drive
to the feed motor.
The wire feeder also controls the main contactor in the power source for safety
reasons. This assures that the welding wire will only be energized when the switch on the
welding gun is depressed.
The wire feeder consists the following:
Wire feed motor with speed control
Feed rollers either knurled or smooth groove
Inlet guide
Centre guide
Outlet nozzle.
The wire feeder motor can be either AC or DC to feed the wire in the speed of 2.5 to 15
meter/min. The capacity varies from 3 to 6 HP and in larger wire feeders to extend of 12 HP. The
wire feed speed is controlled, electronically by a mechanical governed, or by a variable speed
gear box with a constant speed motor.
The wire from the spool is drawn by the motor driven feed and pressure rolls through
inlet guide and straightened and fed in to the welding gun through the outlet nozzle.
The feed rolls, sometimes called drive rolls, pull the wire off the spool or reel, and push it
through a feed cable or conduit to the welding gun. These rolls must usually be changed to
accommodate each different wire diameter, although some rolls are designed to feed a
combination of sizes.

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DRIVE TO ALL DESINGNS OF WIRE FEEDER

The smooth flat V rolls are used for smaller diameter. Hard and soft electrode
wire up to 1.2mm .
Knurled flat rollers with smooth V grooves are used for smaller steel wire to grip
the wire up to 1.2mm .
For larger diameter wires and flux cored wires both knurled V rolls are used. This
reduces the pressure on wires and prevents flattening the wire allowing the flux
not escape from the wire. The wire diameter ranges from 1.6 to 3.2mm .
Both smooth V groove drive roll for soft wire from 1.6 to 3.2mm .
Liner wire feeders are used in full of automatic application.
TYPES OF WIRE FEED MECHANISM
There are four types of wire feed mechanism;
1. Push type
2. Pull type
3. Push & Pull type
4. Linier wire feed mechanism

ANCILARY EQUIPMENTS
In addition to the power source, wire feeder unit and control panel the following
ancillaries are usually provided with a CO2 Welding set.
Pressure regulator: A pressure regulator is necessary to reduce the cylinder pressure (300
1000 lb/in2) to a normal gun working pressure (10 40 lb/in2). Pressure regulators operate on a
simple spring diaphragm principle.

15

Heater:
Contrary to popular belief, the heater used for CO2 welding is not supplied to dry
the gas but to prevent freezing of the pressure regulator when converting the liquid CO2 drawn
from the normal 50 lb siphon cylinder to gaseous CO2.
The heater is simply a cylindrical chamber with an electrically heated element through
which the liquid is drawn and is either a thick wall tube or an expansion vessel provided with a
safety regulator consisting of a thermostat and pressure relief valve.
Flow meter: CO2 welding a flow meter is essential for setting gas flow and to indicate that gas
is passing. An electrical switch is needed to start and stop the welding current; the electrode feed
system, and shielding gas flow.

ELECTRODE
A GMAW electrode is: A metal wire fed through the gun by the wire feeder and
measured by its diameter.
Most steel GMAW electrodes are copper plated as a means of protecting the surface. The
copper inhibits rusting, provides smooth feeding, and helps electrical conductivity.
GMAW electrodes are commonly packaged on spools, reels and coils ranging from 1lb to
1000lbs

16

AWS CLASSIFICATION OF GMAW ELECTRODES

SHIELDING GAS

GMAW welding requires a shielding gas to protect the weld puddle

Shielding gas is usually CO2, argon, or a mixture of both
Purpose of shielding gas is the protect the weld area from the contaminants in the
atmosphere
Gas can be Inert, Reactive, or Mixtures of both
Argon, Helium, and Carbon Dioxide are the main three gases used in GMAW
PROPERTIES OF ARGON GAS

A monatomic, colorless, odorless, tasteless and non-toxic gas.

Argon is non corrosive and non flammable. Process almost same kind of solubility (in water) as
oxygen and low thermal conductivity.

It is only 30 times heavier than air and less reactive than nitrogen

Heavier than other inert gas

Require less quantity for a weld.

17

Argon is extensively used than helium because:

Smoother arc,
Faster arc travel
Lower flow rate- for good shielding
Lower arc voltage at given current level arc length.

PROPERTIES OF CARBON-DI-OXIDE

It is heavy di-atomic gas with combination of carbon and oxygen.

It is obtained as a by-product in the process of the production of alcohol (Molasses) and

aluminum.

It is essentially an inert gas at room temperature, but active gas at an arc temperature gets
disassociated in to the carbon mono-oxide and oxygen, however these gases revert back
as they cool, because it is 50% heavier than air.

Carbon-di-oxide is obtainable in the form of gas, powder and solid (dry ice). Generally
liquid form of gas used.

Carbon-di-oxide is employed in welding of carbon steel, low alloy carbon steel and high
tensile steel.

When CO used alone gives deep bowl shaped penetration.

Atomic weight is 22, and atomic no is 44.

CO cylinder pressure is 30kg/sq.cm or 14 bars.

18

ARC

An electric arc occurs in the gas filled space between the electrode wire and the work
piece

Electric arcs can generate temperatures up to 10,000F

As the wire electrode and work piece heat up and melt, they form a pool of molten
material calledd a weld puddle

This is what the welder watches and manipulates while welding

METAL TRANSFER
The operating characteristics of MIG welding described by the four basic modes of weld
metal transfer from the electrode to the work
1 short circuit transfer
2. Globular transfer
3. Spray transfer
4. Pulsed spray transfer

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The mode of weld metal transfer determined by the following








Welding current
Electrode size
Electrode composition
Electrode stick out
Shielding gas
Power supply characteristics

SHORT CIRCUITING TRANSFER

Short circuiting transfer is a much used method in gas metal arc welding. It is produced
by using the lowest current-voltage settings and the smaller wires, usually 0.8mm, 1.0, and
1.2mm diameters. The low heat input makes this process ideal for sheet metal
applications. Often called "short arc welding" because metal transfer is achieved each time the
wire actually short circuits (makes contact) with the weld puddle. This happens very rapidly.
 Operates at low voltages and welding current
 Small fast-freezing weld puddle obtained
 Useful in joining thin materials in any position, as well as thick materials in vertical and
overhead positions
 Metal transfer occurs when an electrical short circuit is established
 In short arc transfer the electrodes shorts 60 120 times per second

20

Optimum short circuiting arc operating ranges for three mild steel wire sizes with CO2 as shielding gas
are given in the following table.
WIRE SIZE IN MM
PARAMETER
0.8

1.2

1.6

Wire feed rate m/min

2.5

1.7

Arc voltage V

18

19

20

Average current Amps

100

120

160

GLOBULAR TRANSFER
Globular transfer takes place at lower welding currents than spray transfer. There is a
transition current where the transfer changes to globular even when shielding gases using a high
percentage of argon are used. When carbon dioxide (CO2) is used as a shielding gas, the transfer
is always globular.
In globular transfer, a molten drop larger than the electrode diameter forms on the end of the
electrode moves to the outer edge of the electrode and falls into the molten
puddle. Occasionally, a large drop will "short circuit" across the arc, causing the arc to
extinguish momentarily, and then instantaneously reignite. As a result, the arc is somewhat
erratic, spatter level is high, and penetration shallow. Globular transfer is not suitable for out-ofposition welding.
 Welding current and wire speed are increased above maximum for short arc
 Droplets of metal have a greater diameter than the wire being used
 Spatter present
 Welding is most effectively done in the flat position when using globular transfer

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SPRAY TRANSFER
Spray transfer is a high current density process that rapidly deposits weld metal in
droplets smaller than the electrode diameter. They are propelled in a straight line from the center
of the electrode. A shielding gas mixture of Argon with 1% to 2% Oxygen is used for welding
mild and low alloy steel, and pure Argon or Argon-Helium mixtures are used for welding
aluminum, magnesium, copper, and nickel alloys.
Welding current at which spray transfer takes place is relatively high and will vary with
the metal being welded, electrode diameter, and the shielding gas being used. Deposition rates
are high and welding is usually limited to the flat or horizontal fillet position.
 Occurs when the current and voltage settings are increased higher than that used for
Globular Transfer
 Used on thick sections of base material, best suited for flat position due to large weld
puddle
 Spatter is minimal to none
 Very high efficiency process.

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PULSED SPRAY TRANSFER

Pulse transfer is a mode of metal transfer somewhat between spray and short
circuiting. The specific power source has built into it two output levels: a steady background
level, and a high output (peak) level. The later permits the transfer of metal across the arc. This
peak output is controllable between high and low values up to several hundred cycles per
second. The result of such a peak output produces a spray arc below the typical transition
current.
Pulsed spray transfer is a process that combines the lower heat inputs associated with
short arc with the spatter free metal transfer and good penetration associated with spray transfer.
The selection of shielding gas must be adequate enough to support a spray
transfer. Material type, thickness, and welding position are essential variables in selecting a
particular shielding gas.
The following is a list of recommended gases:
Carbon Steel

Argon/CO2/O2/He (He less than 50%)

Alloy Steel

Argon/CO2/O2/He (He less than 50%)

Stainless

Argon/O2/CO2 (CO2 max. 2%)

Copper, Nickel, & Cu-Ni Alloys

Argon/Helium

Aluminum

Argon/Helium

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MIG WELDING PROCEDURES

The welding procedures for MIG welding are similar to those for other arc welding
processes. Adequate fixture and clamping of the work are required with adequate accessibility
for the welding gun. Fixtures must hold the work rigid to minimize distortion from welding. It
should be designed for easy loading and unloading.
Good connection of the work lead (ground) to the work-piece or fixture is required.
Location of the connection is important, particularly when welding ferromagnetic materials such
as steel.
The position of the electrode with respect to the weld joint is important in order to obtain
the desired joint penetration, fusion, and weld bead geometry.

GMAW EQUIPMENT SET UP

1. Connect work clamp
2. Select electrode



Type
Diameter

3. Select shielding gas

4. Turn power supply on
5. Adjust machine output
 Wire feed speed
 Voltage
5. Adjust gas flow rate

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

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ELECTRODE STICK OUT or EXTENSION

Electrode extension (also called stick out) is the distance between the end of the contact
tip and the tip of the electrode. As the electrode extension is increased the electrical resistance
increases and heating of the wire increases. The result is that the amperage necessary for a given
wire diameter is reduced. Too long an electrode extension results in narrow, high crowned weld
bead.
The desirable electrode extension is generally from 6 to 13 mm for short circuiting. The bead
width is the function of arc voltage. The influence of arc voltage on weld is given below:

The extension used is related to the type of MIG welding, short circuiting or spray type transfer.

25

It is important to keep the electrode extension (nozzle-to-work distance) as uniform as possible

during welding.

Therefore, depending on the application, the contact tube may be inside, flush with, or
extending beyond the gas nozzle.
Stick out / Electrode extension

Electrode (mm)

0.8

1.0

1.2

1.6

2.4

Stick out (mm)

6-12

7-13

8-15

13-20

15-30

SHIELDING GAS AND FLOW RATE (LPM)

The gun nozzle size and the shielding gas flow rate should be set according to the
recommended welding procedure for the material and joint design to be welded.
Carbon-di Oxide

8-10

Argon + 25% CO2

6-12

Argon + 1% Oxygen
Argon

15-20
18-0

Joint designs that require long nozzle-to-work distances will need higher gas flow rates
than those used with normal nozzle-to-work distances.
The gas nozzle should be of adequate size to provide good gas coverage of the weld area.

26

SHIELDING GASES ON MIG/MAG WELDING

CO2

Mild steel

Helium

Al, Mg, Cu,.

Argon

Al, Mg, Cu, Ni, Ti,.

Nitrogen

Cu

Argon + 1.5% O2

Al, Low alloy and carbon steels, Stainless steel

Argon + CO2

Mild steel, Low alloy Stainless steel.

MIG WELDING VARIABLES AND PARAMETERS

Work piece thickness
(mm)
1.0 to 2.0

Wire meter (mm)

Current range(Amps)

0.8 to 1.0

50 to 100

2.0 to 4.0

1.0 to 1.2

70 to 120

4.0 to 8.0

1.2 to 1.6

90 to 150

8.0-Above

1.6

140 to 300

2.4

300 to 700

VOLTAGE
Arc voltage

Type of Metal Transfer

Remarks

16-22

Short circuiting

Thin steel sheets

24-30

Both spray and short

circuiting

Semi-automatic and automatic welding of

medium thickness

30-45

Spray type

automatic and automatic welding of thick

section in flat position

Arc voltage to be used depends upon:

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1.
2.
3.
4.
5.

Work piece thickness

Type of joint
Electrode size and its composition
Shielding gas
Welding position, etc.

TORCH ANGLE
The position of the torch and electrode with respect to the joint affects the weld bead
shape and penetration rather than arc voltage or travel speed. The torch is usually maintained
within 10 - 20 on either side of the vertical.
In CO2 welding, the torch can be manipulated by the forehand welding technique or
backhand welding technique. Each welding technique has different characteristics; hence, you
should choose the appropriate technique according to the application.
The forehand welding is adopted in many applications; by contrast, the backhand welding
is more suitable in groove welding with a high current.

FOREHAND WELDING AND BACKHAND WELDING

In CO2 arc welding, the torch can be manipulated by the forehand welding technique or
backhand welding technique. Each welding technique has different characteristics; hence, you
should choose the appropriate technique according to the application.

The forehand welding is adopted in many applications; by contrast, the backhand welding
is more suitable in groove welding with a high current.

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Features of forehand welding:

Easy to target the wire onto the welding line.

Flat bead shape with low reinforcement

Consistent meltthrough root pass bead.

Comparatively large particles of spatter flown ahead

Shallow penetration due to the molten metal flowed ahead.

Features of backhand welding:

Not easy to see the welding line hidden by the sight of nozzle

Narrow bead shape with high reinforcement.

Difficult to obtain a consistent meltthrough root pass.

Low spatter generation

Deep penetration due to the molten pool formed backwards.

Easy to control bead width and reinforcement due to ease of seeing the bead shape.

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STRIKING AN ARC

Position the gun over joint

Position the face shield to protect eyes and face

Pull the gun trigger and begin welding

Maintain a Contact Tip to Work Distance (CTWD) of 10 to 12mm.

Use a uniform travel speed

Most Importantly Watch the Puddle!

Fill the crater by pausing or using a slight back step

Release gun trigger and pull gun away from the work after the arc goes out

Large craters can cause weld cracking

Restart the weld bead by back stepping into the last welds crater and then continue
moving forward

This technique should result in a seamless transition from one weld to the next.

When complete joint penetration is required, some method of weld backing will help to
control it. A backing strip, backing weld, or copper backing bar can be used. Backing
strips and backing welds usually are left in place. Copper backing bars are removable.
MIG WELDING SAFETY OPERATIONS
Pre-Operation
Use this as a basic MIG/MAG welding safety checklist:

Clean and organized work area

Remove flammable liquids from area

Check ventilation

Remove any jewelry and loose clothing

Inspect gas lines for leaks

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Operating MIG Equipment

Clear work area from unauthorized personnel

Position the flash blind in order to protect any nearby personnel

Check cable position to avoid any damage due to sparks or materials that can fall

Check all equipment settings

Much of the risk from welding fumes and smoke can be reduced by using a shielding gas
with a higher percentage of argon and pulse-spray mode of transfer

Remember that wire feeder pushes wire, no need to push gun into arc

Keep nozzles free of spatter. Spatter can build up and electrically connect insulated
nozzle to contact tube. A clean nozzle will have spatter fall off on its' own. You can use
an anti-spatter compound on nozzle and gun and contact tube end. Whatever you do, do
not clean the nozzle by pounding it on a hard surface. It can break and become damaged.

Post Operation

Turn off machine

Firmly close gas cylinder

Return the welding gun to storage

REMEMBER

When welding is done in confined areas or in the root of thick weld joints, small size
nozzles are used.

The gun contact tube and electrode feed drive rolls are selected for the particular
electrode composition and diameter, as specified by the equipment manufacturer.

The contact tube will wear with usage, and must be replaced periodically if good
electrical contact with electrode is to be maintained and heating of the gun is to be
minimized.

The electrode feed rate and welding voltage are set to the recommended values for the
electrode size and material.

With a constant voltage power source, the welding current will be establish by the
electrode feed rate.

A trial bead weld should be made to establish proper voltage (arc length) and feed rate
values.

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Other variables, such as slope control, inductance, or both, should be adjusted to give
good arc starting and smooth arc operation with minimum spatter.

The optimum settings will depend on the equipment design and controls, electrode
material and size, shielding gas, weld joint design, base metal composition and thickness,
welding position, and welding speed.
COMMON WELD DEFECTS
Defect: A discontinuity which exceeds the permissible limit of
requiring repair or replacement

a code. A rejectable discontinuity

Discontinuity: Any interruption of the uniform nature of a metal or any irregularity in the normal pattern
of a material. A rejectable discontinuity is also referred to as a defect.

Weld imperfections and preventive measures

Weld imperfections and preventive measures in CO2 arc welding
CAUSES (PREVENTIVE MEASURES)

WELD IMPERFECTIONS
1) PITS, BLOW HOLES

Shortage of CO2 gas flow rate.

Gas heater does not work.

Purity of CO2 gas is not enough.

Inadequate gas shielding.

Excessive nozzle stands off distances.

Much oil or grease is deposited on the base metal.

Much scale is remained on the base metal.

Much rust is remained on the base metal.

The shielding nozzle is clogged with much spatter.

10 Too long arc length (Too high arc voltage).

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Too low welding current.

Too high welding current.

Too low arc voltage.

Too low welding speed.

Wrong targeting position of the welding wire.

Too small groove angles.

Too high arc voltage.

Too high welding current.

Wrong targeting position of welding wire.

Rough manipulation of the welding torch.

Too high welding speeds.

The center of the wire feed roller is deviated.

Inappropriate adjustment of the wire straightened.

Loosened contact tip.

Too low welding current.

Too low arc voltage.

Too high arc voltages.

Too low welding speed (in groove welding)

Too high welding speed.

Too narrow groove angle.

Wrong targeting position of the welding wire.

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Too large tack weld. Or, welding is directed towards the

preceding weld.
2

Place the work piece cable connection away from the weld

as far as possible (on a large Weldment).

3

On a small Weldment, place the work piece cable

connection at the start of the weld.

4

Keep the arc length shorter

Direct the welding torch toward the opposite direction of the

magnetic arc blow.

6

Put tab plates at both the start and end of the weld line.

Too high welding current.

Too narrow groove.

Too low arc voltage.

Wrong targeting position of the welding wire.

Too large contact tip diameter for the wire diameter used.

Worn contact tip.

Loosened contact tip.

Irregular rotation of the wire reel.

Worn groove of the wire feed roller.

Inadequate pressure of the pressure roller.

Large resistance of the conduit tube.

Too long wire extensions.

Too low or high arc voltages.

10 Too low welding current.

11 Inappropriate welding speeds.
12 Unstable torch manipulations.
13 Nozzle is clogged with much spatter.
14 Fluctuation of wire extension.
15 Wrong targeting position of the welding wire.

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16 Contaminated base metal with dirt such as rust, paint and oil.
17 The position of the work piece cable connection is
inappropriate.
LACK OF FUSION

Possible causes
1
2
3
4

Travel speed is too high

Wrong parameter setting
Pushing technique
Lack of root fusion
Remedies
-Reduce travel

speed/allow more dwell time at edges

-Adjust parameters
-Pulling technique, 70-80 torch angle
- Enlarge root gap
LACK OF PENETRATION

Possible causes
o
o
o
o
o
o

Welding current too low

Arc voltage too high
Travel speed too high
Travel speed too low
Root gap too small
Included joint angle too small

Remedies
 Increase wire feed speed and arc voltage
 Reduce arc voltage
 Reduce travel speed
 Increase travel speed
 Use pulling technique
 Use correct torch angle
 Increase gap and reduce face