GAS METAL ARC WELDING

The Process

1. The arc is shielded by a blanket of gas. Hence the name.

2. The arc is between the filler metal and the base metal.

3. The arc is shielded by the gas, which also protects the molten metal.

4. The shielding gas can be inert ( Argon / Helium ) or active ( Co2 )

5. When the shielding gas is inert the process is called as MIG process.

6. When the shielding gas is active the process is called as MAG process.

7. The filler metal is called as electrode since it is a part of the welding arc.

8. The electrode is consumed continuously in the arc.

9. For continuous feeding, of the electrode is supplied on spools/ coils/ reels.

10. The electrode is fed using a electrode feeder.

11. The electrode diameter can vary from 0.8 mm to 1.6 mm.

12. The power for the arc is DC.

13. The thickness that can be welded can vary from 1.0 mm to 30 mm

14. The welding positions that can be used are flat, horizontal , vertical up, vertical down, overhead
depending on mode of metal transfer.

15. The welding speeds can range from 150 mm / minute to 1500 mm/min.

16. The weld deposition rate can reach up to 6 kg / arc hour .

17. Up to 6 mm of thickness can be penetrated and fused in single pass.

18. The arcing duty can range from 40 to 100 %.

19. The high deposition rate is possible because of high current density.
(amps. / mm2 ) compared to SMAW.

20. The depth of penetration is also higher compared to SMAW because of higher
current density

21. The weld deposition per shift of 8 hours can be in excess of 6 kgs. vis a vis 2 kgs for SMAW.
 The Process Variation using Various Metal Transfer Modes

22. Short Circuit Metal Transfer involves continuous short circuits at frequencies between 20 to 200
Hz. The short circuit takes place when the molten metal drop from the electrode touches the
molten pool on the base metal. After the short circuit, the current rises and the drop detaches from
the electrode by pinch effect. The arc is re established and the next metal drop begins to form at the
electrode and grows in size till the next short circuit happens to repeat the cycle. This transfer
occurs at low currents and low arc voltages less than 22 volts.

23. The Globular Metal Transfer involves transfer of large size molten drops from the electrode to the
molten metal across the arc without any short circuits. The size of the molten drops is more than
the electrode diameter and the direction of transfer is irregular. This transfer occurs at medium
currents and medium arc voltages between 24 and 28 volts.

24. The Droplet / Spray Metal Transfer involves transfer of fine size molten droplets from the
electrode to the molten metal across the arc without any short circuits. The size of the molten
drops is less than the electrode diameter and the direction of transfer is axial. This transfer occurs
at high currents and high arc voltages between 30 and 45 volts.

25. The Pulsed Current Metal Transfer involves transfer of fine size molten droplets from the
electrode to the molten metal across the arc at high current. The current is pulsed between high
and low current to maintain net low heat input. The metal transfer takes place only during the
high current pulse duration.

The Power Source Electrode Feeder Combinations

26. The power for the DC arc can be provided by a constant voltage ( CV )power source.

27. With CV power source, the electrode feeder does not need feed back from arc voltage to maintain
reasonably constant welding current / arc length. The self- regulating arc mechanism helps to
maintain constant arc length for a given wire feed rate, when electrode operates at current densities
in excess of 100 A /mm2

28. The electrode feed rollers and electrode inlet & outlet guides have to be chosen according to the size
and the material of the electrode.

29. The welding gun has to be selected depending upon the length of the reach needed from the
electrode feeder, type of shielding gas to be used and the welding current level & duty cycle.

30. The liner in the welding gun guides and supports the electrode during its passage through the
welding gun. The liner size and type depends upon the electrode size and material. Soft / hard
electrodes wires require different liner material
 Parameter Setting with Single Wire DC using CV Power Source

31. The DC , CV power source provides required current at welding voltage very close to the Open
Circuit Voltage (OCV) which can be set before starting of the arc.

32. The difference between the OCV and arc voltage depends upon the slope of the static characteristic
Current / Voltage curve, the welding current and the voltage drop along the welding cable.

33. The slope of current / voltage curve for CV power sources is between 1 to 3 volts per 100 Amps.

34. The welding current depends upon the chosen electrode feed rate. Higher the electrode feed rate
more the welding current.

35. The electrode stick out ( distance between contact tip end and work piece ) should be between 10 to
15 mm. For currents in excess of 150 Amps stick out should be 15 mm and the contact tip should be
kept flush with the gas nozzle.

36. Two types of shielding gases are used arc namely Active / Inert.

37. Co2 is an active shielding gas while Argon rich gases are inert

38. Gas Flow rate depends upon the welding current level, shielding gas type and electrode material.

39. Argon Rich Shielding Gases provide smoother and spatter free metal transfer.

40. The Co2 shielding gas provides deeper and wider fusion profile .

41. The mixed gases are used to provide optimum combination of smooth spatter free metal transfer,
deeper & wider fusion profile and shiny beads with proper blending with the base metal.

42. CO2 shielding gas needs a gas preheater or special finned gas regulators to be connected to the
cylinders.

43. The electrode should be connected to positive polarity for high depth of penetration.

44. A proper combination of current & voltage has to be selected depending upon the metal transfer
desired and the type of shielding gas chosen.

45. The higher depth of penetration and deposition rate can be obtained by using higher current.

46. For a given current, the depth of penetration and deposition rate is more for smaller diameter
electrode, because of higher current density.

47. The inclination of the electrode with respect to vertical can affect penetration and bead profile.

48. Inclination of the electrode along the direction of welding ( lead angle ) gives flatter beads with
reduced penetration.

49. Inclination of the electrode against direction of welding ( drag angle ) gives lumpy beads with
increased penetration.