with carbon dioxide as the shielding gas, Figs.

21-47 and
Fig. 21-46 GMAW guns from 400 to 100 amperes. Check how
these guns are rated in Table 21-4 Miller Electric Mfg. Co.
wire-feeding mechanism, such as 10 to 15 feet. With a
push-type feeder the gun length should be kept as short as
possible, yet still give the welder access to the weld joint.
Guns are designed for different types of service. An
air-cooled gun may be used for light-duty service and
AB OUT W E L DIN G
Gas Leak
Gas leaking out the back of a MIG gun can
be minimized by a design using a shrink tube wrapping
over the 5 feet of liner right after the wire feeder.
21-48. Carbon dioxide actually assists in the cooling of
the gun. For heavy-duty service and inert gas, the gun
may be water cooled, Figs. 21-49 and 21-50. Coolant is
usually necessary when currents of over 250 amperes are
used. Welding continuously with high current generates
a great amount of heat in the gun. Coolant equipment,
Fig. 21-51 (p. 682), provides a positive system of cooling
the gun. These units have an internal cooling system and
force coolant through thegun.
Guns for semiautomatic operation may be shaped like a
pistol, or have a straight handle or a handle with a gooseneck
nozzle end. All types have a trigger switch that turns on
the controls for the wire feed, shielding gas, and welding-
current contactor.
Nozzles Many different types of materials are used for
nozzles: copper and copper alloys are most common. A
clean smooth nozzle will allow easy removal of weld spat-
ter. The welder should not roughen or abuse the gas nozzle
on the gun. Nozzles are available in various diameters and
lengths. They must be large enough to allow proper gas
shielding, yet small enough to allow access to the weld joint.
Cable Assemblies The cable assemblies are an integral
part of the gun. They generally consist of a single molded
conductor that encloses all the necessary components.
The electrode wire is guided through a flexible liner con-
tained in the cable assembly. The liner is made of spring
steel for strength and protection. Plastic liners are some-
times used for aluminum and magnesium alloys. The
liner serves as a guide for the electrode wire and provides
uninterrupted travel of the wire without buckling or

Table 21-4 GMAW Gun Ratings

Cable Rated Standard Wire Weight

Length (ft) Output (A) Duty Cycle Size (in.) (lb)
10 100 100% with CO2 gas, 60% with mixed gas 0.0300.035 3.2
10 150 100% with CO2 gas, 60% with mixed gas 0.0300.035 4.4
12 4.7
15 6.0
10 250 100% with CO2 gas, 60% with mixed gas 0.0300.035 5.4
12 6.0
15 0.0300.035 7.2
0.0350.045
15 250 100% with CO2 gas, 60% with mixed gas 0.0300.035 7.5
10 400 100% with CO2 gas, 60% with mixed gas 0.0350.045 8.3
12 9.5
15 10.9

Source: Miller Electric Manufacturing Company. Copyright Miller Electric Manufacturing Company. All rights reserved. Used with permission

680 Chapter 21 Gas Metal Arc and Flux Cored Arc Welding Principles
Fig. 21-47 Internal components of GMAW/ 1 2 3 4 5 6 7 8
FCAW gas shielded welding gun. 1.Nozzle. 2.Con-
tact tip. 3. Contact tip adapter. 4.Nozzle adapter.
5. Retaining ring. 6. O-ring. 7.Shock washer. 8.
Head tube. 9. Handle locking nut. 10. Jam nut. 11. 9
Cable connector. 12.Connector nut. 13. Unicable 10
11
clamping kit. 14. Compression clip. 15. Support
tube. 16.Inner clamp. 17. Jacket clamp. 18. Switch 12
lead connector. 19. Handle. 20. Cable strain relief. 14
15 24 26
21. Trigger cord assembly. 22. Feeder connection. 13
16
23. O-ring. 24. Monicoil liner kit. 25. O-ring. 26.
Outlet guide. 27. Trigger switch. Source: Miller 22
17
Electric Manufacturing Company. Copyright Miller 23 25
Electric Manufacturing Company. All rights reserved.
19
Used with permission
21
15 21
18 20
9
10
11
12
17
19
20

kinking from the drive The gas from the

rolls to the contact tip of cylinder is controlled
the gun. The cable also by means of a pressure-
contains tube passages reducing regulator, flow-
for shielding gas flow. meter, and the solenoid
Dirt and foreign ma- control valves. It is fed
terial gradually build up to the torch through an
Fig. 21-48 FCAW-S guns rated inside the liner and in- innerconnecting hose
from 250 to 600 amperes. Note the terfere with the free flow system. Some power
exposed contact tips on the guns of the electrode wire supplies have certain of
set up for short electrode extension through the cable. The these units incorporated
electrodes and the insulated guide liner should be blown out into the machine. It is
tubes on other guns for the long Fig. 21-49 A water-cooled gun
electrode extension electrodes. each time the electrode important that the cor- rated at 450 amperes with carbon
Use the appropriate gun setup per wire spool is changed. rect regulators and flow- dioxide shielding and 400 amperes
the manufacturers specification Short cable assemblies meters be used with the with argon or argon mixed gases at
100 percent duty cycle. Lincoln
for the FCAW electrode exten- allow for easier feeding particular shielding gas Electric
sion being used. Miller Electric and keep the cable as being employed. The gas
Mfg. Co.
straight as possible. cylinders can be replaced
with a central gas sup-
The Shielding Gas System ply system when there
is a sufficient volume
The shielding gas system supplies and controls the flow
of MIG/MAG welding
of gas that shields the arc area from contamination by the
being done.
surrounding atmosphere. The system consists of the fol-
To reduce waste
lowing equipment:
and misadjustment of Fig. 21-50 To help reduce fumes
One or more gas storage cylinders (or bulk-manifolded flow devices, a fixed some guns are equipped with extrac-
system) orifice in-line sys- tor devices directly above the gas
Hose delivering nozzle system. This gun is
tem can be used. The
so equipped, is water cooled, and is
Pressure-reducing regulator manifold system must rated at 300 amperes at 100 percent
Flowmeter have the pressure regu- duty cycle with carbon dioxide
Solenoid control valves lated very accurately to shielding. Lincoln Electric

Gas Metal Arc and Flux Cored Arc Welding Principles Chapter 21 681
 Fig. 21-51 Water-circulating units of various profiles for cooling heavy-duty MIG/MAG guns. Miller Electric Mfg. Co.
each feeder system for this to be useful. Another waste
in shielding gas is leaks. Leak checks can quickly be
done by observing pressure drop. If the system is not
in use and the cylinder valve(s) or manifold system is
shut down, the pressure should hold. If a pressure drop is
noted, the leak must be found. Detection devices as well
as liquid leak detection material are available. Not only
are leaks an indication of waste and possible safety is-
sues in confined or low spaces (many common shielding
gases are heavier than air), but if they are in a volume
flow rate area, they may cause contamination. This is
referred to as the venturi effect, where a high velocity on
the inside of the pipe or gas hose will cause a low pres-
sure in relationship to the outside and will draw air into
the system. This will contaminate the gas and result in
porosity and oxide formation in the welds.
Gas Flow Rates In order to provide a good gas shield, the
gas must be fed through the nozzle at such a rate as to en-
sure laminar flow (a straight line of flow), Fig.21-52. If the
flow rate is too high, it causes turbulence (swirling). The
turbulent gas shield mixes with the surrounding air under
Nozzle
Laminar Turbulent
Shielding Shielding
Gas Flow Gas Flow
Fig. 21-52 For an effective gas shield, the gas should be fed
through the gun nozzle in a laminar flow (left). A swirling gas shield
results in contamination of the weld deposit (right).
682 Chapter 21 Gas Metal Arc and Flux Cored Arc Welding Principles
the nozzle and causes contamination of the weld deposit.
If the gas shield fails to cover the arc or is contaminated,
porosity results. Almost all porosity in MIG/MAG welds
is caused by poor gas coverage. Too much is just as bad as
too little.
The gas flow rate is a function of the shape and cross-
sectional area of the gas passages in the nozzle. The rec-
ommended gas flow rate for a particular nozzle and a
specified gas is suitable for all wire-feed speeds. Some
mfg. have nozzles with a diffuser or lens similar to the
gas lens on a GTAW torch to give a more uniform pat-
tern to the gas flow. Always refer to the manufacturers
instructions for recommendations concerning a particular
nozzle.
For video of GMAW gun nozzle comparing
gas flow patterns, please visit
www.mhhe.com/welding.
Specific Gravity The chief factor influencing the effective-
ness of a gas for arc shielding is the specific gravity of the
gas. This in turn determines the flow rate selected for the
welding operation. The specific gravity of a gas is a mea-
sure of its density relative to the density of air. The den-
sity of air is fixed as one. The specific gravity of helium
is 0.137, or approximately 110 as heavy as air. Thus helium
tends to rise quickly from the weld area, and a high flow
rate is needed to provide adequate shielding. A gas of low
density such as helium is also greatly affected by cross-
drafts of air across the arc and weld pool.
Argon and carbon dioxide are much heavier than he-
lium, and lower flow rates are required for equivalent
shielding. The specific gravity of argon is 1.38, and the
specific gravity of carbon dioxide is 1.52. Both gases,
therefore, are heavier than air. They blanket the weld area.
Carbon dioxide has the advantage of being heavier than
argon, thus ensuring good protection. It is also more re-
sistant to crossdrafts.
Other Factors Affecting Flow Rates Flow rates may vary from
15 to 50 cubic feet per hour depending upon the type and
thickness of the material to be welded, the position of the
weld, the type of joint, the shielding gas, and the diameter
of the electrode wire. The welder can tell if the amount
of shielding gas is correct by the rapid cracking and siz-
zling arc sound. Inadequate shielding produces a popping,
erratic sound and a considerable amount of spatter. The
weld is also discolored and has a high degree of porosity.
The following additional factors also have an influence
on effective gas shielding:
Size and shape of the nozzle
Nozzle-work distance (standoff distance)
Size of the weld pool
Amount of welding current
Air currents
Design of welding fixture
Welding speed
Joint design (fillet weld vs. outside corner)
Inclination of the torch
Excessive shielding gas pressure
Leaking gas fittings
Shielding Gases
Metals are meeting the stringent requirements of the
space age with their high corrosion resistance, excellent
strength-to-weight ratios, and good physical properties.
Add the advantages of welded fabrication, and the metals
become an engineers dream come true.
However, in the molten state, many of the metals ab-
sorb oxygen, nitrogen, and hydrogen from the air. These
gases cause porosity and brittleness. The prime consid-
eration when welding them is protection of the weld zone
from atmospheric elements. In Chapter 18, we have seen
that this is accomplished by a shielding gas.
Selecting a shielding gas for MIG/MAG welding can
be a problem. Arc atmosphere governs, to a large extent,
arc stability, bead shape, depth of penetration, freedom
from porosity, and allowable welding speed. Considering
these points along with the cost of various gases will lead
to the best choice.
The three principal gases for TIG and MIG/MAG
welding are argon, helium, and carbon dioxide. These
three gases coupled with the two welding processes are
producing the porosity-free welds specified for the mis-
siles, rockets, jets, and nuclear reactors that are fabricated
from space-age metals.
For MIG welds, gases used singly or in mixtures can
be completely inert. If such an atmosphere is desired,
argon or helium with a purity greater than 99.9 percent
may be best. Other inert gases (xenon, krypton, radon,
and neon) are too rare and expensive. MAG welds
would use reactive gases like carbon dioxide, oxygen,
and hydrogen.
Study Tables 21-5 and 21-6 (p. 684) carefully, and you
will have a good understanding of the proper shielding
gas to use for a given situation.

Table 21-5 Proper Wire and Gas Combinations

Mild Steel and Mild Steel

Mild Steel Alloy Metal and Alloy Flux
Solid Wire Cored Wire Cored Wire Aluminum Copper Stainless Bronze
Carbon dioxide X X X X
75% argon + 25% carbon X X X X
dioxide
90% argon + 10% carbon X X X X
dioxide
100% argon X X
9598% argon + 52% oxygen X X X X
100% helium X X
75% helium + 25% argon X X
90% helium + 7% argon + X
2% carbon dioxide
Table lists wire and gas combinations for semiautomatic welding.

Gas Metal Arc and Flux Cored Arc Welding Principles Chapter 21 683
 Table 21-6 Gas Selection for Gas Metal Arc Welding

Recommended
Metal Type Thickness Transfer Mode Shielding Gas Advantages/Description
Carbon steel Up to 14 gauge Short circuit Argon + CO2 Good penetration and distortion control to
Argon + CO2 + O2 reduce potential burn-through.
14 gauge18 in. Short circuit Argon + 8 to 25% CO2 Higher deposition rates without burn-through.
Argon + He + CO2 Minimum distortion and spatter. Good pool
control for out-of-position welding.
Over 18 in. Short circuit Carbon dioxide High welding speeds. Good penetration and
Argon + 1525% CO2 pool control. Applicable for out-of-position
welds.
Short circuit Argon + 25% CO2 Suitable for high current and high speed
globular welding.
Short circuit Argon + 50% CO2 Deep penetration; low spatter; high
travel speeds. Good out-of-position welding.
Short circuit Carbon dioxide Deep penetration and fastest travel
globular speeds but with higher melt-through
(buried arc) potential. High current mechanized welding.
Spray transfer Argon + 18% O2 Good arc stability; produces a more fluid pool
as O2 increases; good coalescence and bead
contour. Good weld appearance and pool
control.
Spray transfer Argon + 520% CO2 Fluid pool and oxidizing to weld metal
causing higher amounts of oxides and
scale, as CO2 increases. Good arc stability,
weld soundness, and increasing width of
fusion.
Short circuit Argon + CO2 + O2 Applicable to both short-circuiting and spray
Spray transfer Argon + He + CO2 transfer modes. Has wide welding current
Helium + Ar + CO2 range and good arc performance. Weld pool
has good control which results in improved
weld contour.
High current Argon + He + CO2 + O2 Used for high deposition rate welding where
density Argon + CO2 + O2 1530 lb/h (7 to 14 kg/h) is typical.
rotational Special welding equipment and techniques
are sometimes required to achieve these
deposition levels.
Over 14 gauge Pulsed spray Argon + 28% O2 Used for both light gauge and heavy out-
Argon + 520% CO2 of-position weldments. Achieves good
Argon + CO2 + O2 pulse spray stability over a wide range
Argon + He + CO2 of arc characteristics and deposition
ranges.
Low and high Up to 332 in. Short circuit Argon + 820% CO2 Good coalescence and bead contour. Good
alloy steel Helium + Ar + CO2 mechanical properties.
Argon + CO2 + O2
Short circuit Argon + 2050% CO2 High welding speeds. Good penetration and
globular pool control. Applicable for out-of-position
welds. Suitable for high current and high
speed welding.
Over 332 in. Spray transfer Argon + 2% O2 Reduces undercutting. Higher deposition
(high current Argon + 510% CO2 rates and improved bead wetting.
density & Argon + CO2 + O2 Deep penetration and good mechanical
rotational) Argon + He + CO2 + O2 properties.
Low and high Pulsed spray Argon + 2% O2 Used for both light gauge and heavy out-of-
alloy steel Argon + 5% CO2 position weldments. Achieves good pulse
Argon + CO2 + O2 spray stability over a wide range of arc
Argon + He + CO2 characteristics and deposition ranges.

684 Chapter 21 Gas Metal Arc and Flux Cored Arc Welding Principles
 Table 21-6(Concluded)

Recommended
Metal Type Thickness Transfer Mode Shielding Gas Advantages/Description
Steel, stainless, Up to 14 gauge Short circuit Argon + 2 to 5% CO2 Good control of burn-through and distortion.
nickel, nickel Used also for spray arc welding. Pool fluidity
alloys sometimes sluggish, depending on the base
alloy.
Over 14 gauge Short circuit Helium + 7.5 Ar + 2.5 CO2 Low CO2 percentages in He mix minimizes
Argon + 25% CO2 carbon pickup, which can cause
Argon + He + CO2 intergranular corrosion with some
Helium + Ar + CO2 alloys. Helium improves wetting action
and contour. CO2 percentages over
5% should be used with caution on
some alloys. Applicable for all position
welding.
Spray transfer Argon + 12% O2 Good arc stability. Produces a fluid but
Argon + He + CO2 controllable weld pool; good coalescence and
Helium + Ar + CO2 bead contour. Minimizes undercutting on
heavier thicknesses.
Stainless steel Over 14 gauge Pulsed spray Argon + 12% O2 Used for both light gauge and heavy
Argon + He + CO2 out-of-position weldments. Achieves
Helium + Ar + CO2 good pulse spray stability over a wide
Argon + CO2 + H2 range of arc characteristics and deposition
ranges.
Copper, copper- Up to 18 in. Short circuit Helium + 10% argon Good arc stability, weld pool control and
nickel alloys Helium + 25% argon wetting.
Argon + helium
Over 18 in. Spray transfer Helium + argon Higher heat input of helium mixtures
Argon + 50% helium offset high heat conductivity of
Argon or helium heavier gauges. Good wetting and bead
contour. Can be used for out-of-position
welding. Using 100% helium on heavier
material thickness improves wetting and
penetration.
Pulsed spray Argon + helium Used for both light gauge and heavy out-
of-position weldments. Achieves good
pulse spray stability over a wide range
of arc characteristics and deposition
ranges.
Aluminum Up to 12 in. Spray transfer Argon Best metal transfer, arc stability, and plate
pulsed spray cleaning. Little or no spatter. Removes
oxides when used with DCEP (reverse
polarity).
Over 12 in. Spray transfer Helium + 2050% argon High-heat input. Produces fluid pool, flat bead
pulsed spray Argon + helium contour, and deep penetration. Minimizes
porosity.
Magnesium, All thicknesses Spray transfer Argon Excellent cleaning action. Provides more stable
titanium, arc than helium-rich mixtures.
& other
reactive
metals
Spray transfer Argon + 2070% helium Higher heat input and less chance of
porosity. More fluid weld pool and improved
wetting.

Gas Metal Arc and Flux Cored Arc Welding Principles Chapter 21 685
 Argon Argon is in abun-
dant supply. The amount of
air covering one square mile
of the earths surface con-
tains approximately 800,000
pounds of argon. The gas is a
by-product of the manufacture
of oxygen.
In the argon shield, the
welding arc tends to be
more stable than in other gas
shields. For this reason, argon
is often used as a mixture with
Fig. 21-53 Argon-
shielded weld.
other gases for arc shielding.
The argon gives a quiet arc
and thereby reduces spatter.
Argon has low thermal (heat) conductivity. The arc
column is constricted so that high arc densities are pro-
duced. A high arc density permits more of the available
arc energy to go into the work as heat. The result is a
relatively narrow weld bead with deep penetration at the
center of the deposit, Fig. 21-53. In some welding appli-
cations, however, argon does not provide the penetration
characteristics needed for thicker metals.
Argon ionizes more readily than helium, and thus can
transmit some electric energy. Therefore, argon requires a
lower arc voltage for a given arc length than helium does.
Since the result is less heat, it is believed that the argon arc
is not as hot as the helium arc. The cooler arc produced
with argon makes it preferable for use in welding light
gauge metal and materials of low thermal conductivity.
Pure argon is used in MIG welding (however, pure
argon is not used for MAG welding) of such materials
as carbon steel since it causes poor penetration, under-
cutting, and poor bead contour. Its primary use is in the
welding of nonferrous metals such as copper and alloys
containing aluminum and magnesium.
The combination of constricted penetration and re-
duced spatter makes argon desirable when welding in
other than the flat position. Argon is recommended for
manual operations because changes in arc length do not
produce as great a change in arc voltage and heat input to
the work as when helium is used.
Helium Helium is produced from natural gas. Natural
gas is cooled and compressed. The hydrocarbons are
drawn off first, then nitrogen, and finally helium. The
gases are liquified until helium is produced at 345F.
Helium is a light gas that tends to rise in a turbulent fash-
ion and disperse from the weld region. Therefore, higher
flow rates are generally required with helium than with
argon shielding. Helium, because of greater arc heat, is
686 Chapter 21 Gas Metal Arc and Flux Cored Arc Welding Principles
usually preferable for welding
heavy sections and materials
with high thermal conductiv-
ity. It produces a wider weld
bead with slightly less penetra-
tion than argon, Fig.21-54.
When pure heliumis used
with MIG and DCEP, there
is no cleaning a ction. Metal
transfers from the electrode
in large drops and tends to
spatter. The beads are broad
and flat, and penetration is
uniform. Helium lacks the Fig. 21-54 Helium-
deep central penetration of shielded weld.
argon. For a given current
and arc length, arc voltage is higher and wire burnoff is
greater than with argon.
Helium is used more with automatic and mechanized
processes than argon because control of arc length is not
a problem. It is used primarily for the nonferrous met-
als such as aluminum, magnesium, and copper and their
alloys.
Carbon Dioxide Carbon dioxide (CO2) is not an inert gas
such as argon or helium. It is a chemical compound com-
posed of one part carbon (C) and two parts oxygen (O2). It
is manufactured from flue gases that are given off by the
burning of natural gas, fuel oil, and coke. Carbon diox-
ide is also a by-product of the manufacture of ammonia
and the fermentation of alcohol. The carbon dioxide from
these processes is almost 100 percent pure.
The use of carbon dioxide as a shielding gas is increas-
ing. It is cheaper than the inert gases and has several de-
sirable characteristics. It produces a wide weld pattern and
deep penetration, thus making it easier to avoid incom-
plete fusion. The bead contour is good, and there is no
tendency toward undercutting.
One disadvantage of carbon dioxide is the tendency
for the arc to be unstable and cause weld spatter. This is
particularly serious on thin materials when appearance is
important. The amount of weld spatter may be reduced by
maintaining a very close arc. On heavier materials, the arc
may be buried in the workpiece. Spatter can also be re-
duced by using the FCAW process.
The oxidation effect of the carbon dioxide shield is
about equal to a mixture of 91 percent argon and 9percent
oxygen. Under a carbon dioxide shield, about 50 percent of
the manganese and 60 percent of the silicon in the weld-
ing wire are converted to oxides as it passes through the
arc. It is for this reason that the electrode wire contains a
balance of deoxidizers and that a short arc is maintained.