insulation in the nozzle breaks, and damaged insulation
causes arcing in the handles. Trigger switches are broken,
ABOUT W E L DIN G
The First Welded Bridges
A 62-foot long bridge in Pittsburgh was
the United States first all-welded one for trains. In 1928
it was revolutionary in that it used no rivets. To test it out,
they drove a locomotive over it! Itwas built and used by
Westinghouse. Its European counterpart, designed in 1927,
was over a river in Poland. It lasted 50 years until it was
replaced by a wider version.
itself is a natural spatter collector, Fig. 22-17. It surrounds
the contact tube and provides a good target area as the
spatter flies out of the arc stream. This will cause poor
shielding.
If the spatter builds up thick enough, it can actually
bridge the gap and electrically connect the insulated noz-
zle to the contact tube. If you accidentally touch the noz-
zle to a grounded surface when this happens, there will be
a flash. It is quite likely the nozzle will be ruined. If the
face of the nozzle is burned back, the shielding gas pattern
over the arc may be changed so much that the nozzle must
be replaced.
To remove spatter, use a soft, blunt tool such as an ice
cream stick for prying. If the nozzle is kept clean, shiny,
and smooth, the spatter almost falls out by itself. An an-
tispatter compound may be applied to the gun nozzle and
contact tube end. However, the root cause of the spatter
should be found and corrected. Antispatter should not be
used to cover up a problem.
Do not clean guns or torches by tapping or pounding
them on a solid object. Bent gun nozzles distort the gas
pattern. Threads are damaged so that it is difficult to re-
place nozzle tips and contact tubes. The high temperature
Fig. 22-17 This plugged gun nozzle is an example of improper
care of welding equipment, which can damage parts.
Gas Metal Arc Welding Practice with Solid and Metal Core Wire: Jobs 22-J1J23 (Plate) Chapter 22 723
and in the case of water-cooled guns, leaks are sure to
develop.
Care of Contact Tubes
The contact tube transfers the welding current to the elec-
trode wire. New contact tubes have smooth, round holes
of the proper minimum diameter. The hole has to be big
enough to allow a wire with a slight cast to pass through
easily.
With use, the wire wears the hole to an oval shape,
especially on the end closest to the arc. The wire slides
more easily, but the transfer of current is not as good.
Arcing in the tube results, and movement of the wire
can actually be stopped. When this happens, the contact
tube has to be replaced. It is not a good idea to salvage
these tubes.
When the hole in the contact tube becomes too big
through wear, spatter flies up into the bore and wedges
against the wire. The wire slows down because of the
friction. Spatter in the tube also produces a long arc that
burns back up to the contact tube and fuses the wire to
the tube. Worn contact tubes also allow the wire to flop
around as it emerges from the gun so that it is difficult to
track a seam. It can also result in poor arc starts.
The contact tube must be tightly secured in the gun.
With the heating and cooling of the gun it may loosen over
time. Periodically check the contact tube for tightness.
Care of Wire-Feed Cables
The wire-feed conduit is not unlike an automobile speed-
ometer cable. It is a flexible steel tube that does not
stretch. Because wire-feed cables are the main source of
friction in the wire-feed system, they should always be as
clean and straight as possible. When welding, do not lay
the cables in a loop or bend them around a sharp corner.
Bending pinches the wire.
Under normal operating conditions, steel and copper
chips loosened by the driving action of the feed rolls rub
off the wire and collect in the wire-feed cables. If these
chips are allowed to collect for any period of time, they
fill up the clearance between the wire and the cable and
jam the wire. It is not uncommon for this type of stoppage
to completely ruin a feed cable. Jerky wire feeding is an
indication of chip buildup.
Wire-feed cables should be cleaned with dry com-
pressed air. The conduit should be removed at the feed
roll end, and the air nozzle placed on the tip of the contact
tube. This results in a reverse flush. Lubricating a blown-
out wire-feed cable with dry powdered graphite reduces
the friction in the cable and results in smooth wire feed- Outlet Guide to Gun
ing. Wear safety glasses when cleaning and lubricating
the cable. Wire

Do not put so much lubricant in the cable that there Drive Rolls
is not room for chips. Pour about 14 teaspoon of graphite Drive Roll Groove
into the feed end of the cable. Blow the graphite through
the cable and reassemble the cable and wire driver. Wire- Inlet Guide
feed cables should be cleaned every time a spool or coil
is changed. Wire-feed Cable
Liquid lubricating compounds should be avoided be- A B
Proper Improper
cause a paste is formed with the chips that tends to pack Vertical Vertical
very lightly. If a liquid lubricant has been applied, clean- Alignment Alignment
ing with compressed air does not work. The cable must
be washed with a solvent. This is not only messy, but C
time-consuming. Improper
Horizontal
Alignment
Bird Nesting
Occasionally, the wire coils sideways between the wire-
Outlet Guide
feed cable and the drive rolls. This happens with greater to Gun
frequency when small wires are pushed because the column
strength (stiffness) of the small wire is not great enough to D Wire
withstand the push of the drive motor. Worn contact tubes Proper Alignment
Keeps Inlet and Outlet Drive Rolls
and other sources of friction previously discussed increase Guides Close to the
the chances of a bird nest. Wire Drive Rolls
Inlet Guide
Bird nesting can be prevented by accurate alignment of
Wire-Feed
the wire-feed cable inlet guide. The inlet guide should be Cable
aligned exactly with the rollers so that the wire does not
have to make a reverse bend, Fig. 22-18A, B, and C. It
Wire
should be as close to the rollers as possible without touching
Drive Rolls
them, Fig. 22-18D. The notch in the drive rolls must be in
perfect alignment to provide smooth passage for the wire, E F
Proper Alignment Improper Alignment
Fig. 22-18E and F. of Drive Rolls of Drive Rolls

Cleanliness of the Base Metal Fig. 22-18 Wire-feed alignment.

The gas metal arc process produces quality welds free of

porosity and cracks when welding on steels that have been
cleared of rust, scale, burned edges, and chemical coating.
The quantity and type of the contamination that can be
tolerated varies from application to application.
These contaminants by and large are gas producers. On
high speed applications the weld metal solidifies before
the gas has a chance to float to the surface and escape.
Porosity is the result. On slow speed applications porosity
is not as common. The gas has a chance to escape from
the molten metal, and some of the contaminant actually
has time to burn away in front of the crater because of the
intense heat of the arc. This reduces the amount of gas
formed quite effectively.
A good general rule to follow is to clean the area
thoroughly before welding. Good ventilation is essential
when welding galvanized, zinc-coated, aluminum-coated,
cadmium-plated, lead-plated, and red-lead-painted sur-
faces to prevent breathing toxic fumes.
Arc Blow
You will recall from your practice with shielded metal arc
welding that arc blow is always a problem when welding
with direct current whether it is electrode negative or posi-
tive polarity.
To understand what arc blow is, think of the ionized
gases carrying the arc from the end of the electrode wire
to the work field as a flexible conductor. This conductor
has a magnetic field around it. If it is placed in a loca-
tion such as the corner of a joint or the end of a plate, the

724 Chapter 22 Gas Metal Arc Welding Practice with Solid and Metal Core Wire: Jobs 22-J1J23 (Plate)
magnetic field is distorted and pulled in another direction.
The magnetic field reacts to this force by trying to re-
turn to a state of equilibrium. The magnetic field actually
moves the flexible conductor to another location where
the magnetic forces are in balance. Thus we have a condi-
tion of pull and counter-pull: the arc is blown to one side
or the other as if by a draft. Hence, the term arc blow.
Arc blow does not occur with a.c. welding arcs because
the forces exerted by the magnetic field on the flexible
conductor are reversed 120 times (60 cycles) per second.
This tends to keep the magnetic field and the flexible con-
ductor in a constant state of equilibrium. Because of the
short arc length in the GMAW process, arc blow is not as
prevalent as with other processes like SMAW.
Connecting the Work to Minimize Arc BlowThe re-
turn path for the welding power from the workpiece to
the power source is just as important as the path from the
power source to the electrode. The following suggestions
will shorten the trial-and-error process of locating the
best work connection location:
Attach the work lead or leads directly on the work-
piece if possible. Do not connect through ball or roller
bearings, hinges, a hold-down clamp, or swivels. Re-
move rust or paint on the weldment at the point of the
connection.
Connect both ends of long, narrow weldments.
Use electrical conductors of the proper length. Extra-
long cables that must be coiled up act as a reactor.
Stray magnetic fields that affect the action of the arc
are also set up.
Weld away from the work connection.
On parts that rotate, use a rotating work connection or
allow the work cable to wind up no more than one or
two turns.
In making longitudinal welds on cylinders, use two
work connectionsone on each side of the seam as
close as possible to the point of starting.
If multiple work connections are necessary, make sure
that the cables are the same size and length and that
they have identical terminals. Both cables should run
from the workpiece to the power source.
On multiple-head installations, all heads should
weld in the same direction and away from the work
connection.
Use individual work circuits on multiple-head
installations.
Do not place two or more arcs close to one another
on weldments that are prone to magnetic disturbance
with one arc such as tubes or tanks requiring longitu-
dinal seams.
Gas Metal Arc Welding Practice with Solid and Metal Core Wire: Jobs 22-J1J23 (Plate) Chapter 22 725
Setting Up the Equipment
Examine the photographs of gas metal arc equipment
in Chapter 21. Figure 22-19 shows an MIG/MAG weld-
ing station in the plant. The following equipment is
required:
Constant voltage d.c. power source. The weld-
ing machine may be engine driven or a static
transformer-rectifier.
Wire-feeding mechanism with controls and spooled or
reeled filler wire mounted on a fixture.
Gas-shielding system consisting of one or more cyl-
inders of compressed gas, depending on the gas mix-
ture, pressure-reducing cylinder regulator, flowmeter
assembly. (The regulator and flowmeter may be sepa-
rate or a combination device.)
Combination gas, water, wire, and cable control
assembly and welding gun of the type and size for the
particular job.
Connecting hoses and cables, work lead, and work
clamp.
Face helmet, gloves, sleeves (if necessary), and an as-
sortment of hand tools.
The following safety precautions are assumed.
The welding equipment has been installed properly.
The welding machine is in a dry location, and there is
no water on the floor of the welding booth.
The welding booth is lighted and ventilated properly.
All connections are tight, and all hoses and leads
are arranged so that they cannot be burned or
damaged.
Fig. 22-19 Typical gas metal arc welding station in industry.
Note the inverter power source with microprocessor-based wire-
feeder/controller on this steel back-hoe bucket. Miller Electric
Mfg. Co.
 Gas cylinders are securely fastened so that they cannot
fall over and are not part of the electrical circuit.
Starting Procedure
1. Check the power cable connections. Connect the
gun cable to the proper welding terminal on the
welding machine. Make sure that the work cable end
is connected to the proper terminal on the welding
machine. (For DCEP the cable should be connected
to the negative terminal.) Connect the work cable
clamp to either the work or the work table.
2. Start the welding machine by pressing the on button
or, in the case of an engine drive, start the engine.
3. Turn on the wire-feed unit. Make sure that the wire
and feed rollers are clean and properly adjusted.
4. Check the gas-shielding supply system. Make
sure that it is properly connected and that all con-
nections are tight. Open the gas cylinder valve.
Open the flowmeter valve slowly, and at the same
time squeeze and hold down the gun trigger. Ad-
just the gas flow rate for the particular welding
operation you are about to perform. It is usually
15 to 25cubic feet per hour. Release the gun
trigger.
5. Check the water flow if the gun is water cooled.
6. Set the wire-feed speed control for the type and size
of filler wire and for the particular job. Remember
that the wire-feed speed determines the welding
current in a constant voltage system. If you find that
more current is required during welding, increase
the wire-feed speed. If less current is required, de-
crease the wire-feed speed. The current value can
be checked on the ammeter only while welding.
Wire-feed speed determines deposition and welding
speed, so adjust speed accordingly.
7. The voltage rheostat should be set to conform to the
type and thickness of material being welded, the
diameter of the filler wire, the type of shielding gas,
and the type of arc. Voltage may range from 18 to
as high as 32 volts. The lower voltages are normally
used for thinner metals at low amperages with the
short circuit mode of transfer. For heavier materials
the higher voltage and amperage values apply with a
spray arc. Adjust the voltage rheostat until you get a
smooth arc.
8. Adjust for the proper electrode extension beyond
the contact tube. This varies slightly to meet dif-
ferent welding conditions. Usually a minimum of
1
4 inch and a maximum of 58 inch are satisfactory.
The tip of the tube is sometimes flush with the
nozzle surface to maintain normal extension.
726 Chapter 22 Gas Metal Arc Welding Practice with Solid and Metal Core Wire: Jobs 22-J1J23 (Plate)
An extended tube is used for very low amperages
and the short circuit transfer. For spray arcs the
tube is normally recessed for a distance of no more
than 18 inch from the nozzle opening. The distance
from the nozzle to the work may vary from 12 to 1
inch maximum.
9. To start the arc, touch the end of the electrode wire
to the proper place on the weld joint, usually just
ahead of the weld bead, with the current shut off.
Lower your helmet and then press the gun trigger
on the torch. Depressing the gun trigger on the
torch causes the wire to feed, the current to flow,
and the shielding gas to flow. Do not press the trig-
ger on the torch before you are ready to start weld-
ing. If this happens, cut off the excessive filler wire
extending out of the nozzle with a pair of wire cut-
ters or pliers. A steady crackling or hissing sound
of the arc is a good indicator of correct arc length
and wire feed.
Shutting Down the Equipment
1. Stop welding and release the gun trigger.
2. Return the feed speed to the zero position.
3. Close the gas outlet valve in the top of the gas
cylinder.
4. Squeeze the welding gun trigger, hold it down, and
bleed the gas lines.
5. Close the gas flowmeter valve until it is f inger-tight.
This will prevent the possibility of breaking the
glass tube on the flowmeter when the gas cylinder is
turned on again.
6. Shut off the welding machine and wire feeder.
7. Hang up the welding gun and cable assembly.
Welding Technique
Make sure that the filler wire is of the correct type and
size for the type of metal, type of joint, and thickness of
metal being welded. Shielding gas flow, power supply,
and wire-feed speed should be adjusted for the welding
procedure employed. Voltage and wire-feed speed (cur-
rent) are interdependent with a constant voltage power
supply. Adjustment of one may require readjustment of
the other.
Starting the Weld
The arc is started with either a running start or a scratch
start. In the running start, the arc is started at the begin-
ning of the weld. The electrode end is put in contact with
the base metal, and the trigger on the torch is pressed.
Because this type of start tends to be too cold at the
beginning of the weld, it may cause poor bead contour,
incomplete penetration, incomplete fusion, and porosity
at this point.
The scratch start usually gives somewhat better re-
sults. In this type of start, the arc is struck approximately
1 inch ahead of the beginning of the weld. Then the arc
is quickly moved back to the starting point of the weld,
the direction of travel is reversed, and the weld is started.
The arc may also be struck outside of the weld area on
a starting tab.
Finishing the Weld
When completing the weld bead, the arc should be
manipulated to build up the weld crater. The gun trigger
can be turned on and off several times at the end of a weld
to fill the crater. Another method is reversing the travel
direction at the end of the weld and leaving the crater on
top of the weld, not at the end of the weld. The gun should
be kept over the weld until the gas stops flowing in order
to protect the weld until the metal has solidified.
Travel Angle
A push travel angle of 5 to 15 is generally employed when
welding in the flat position. Care should be taken that the
push angle is not changed or increased as the end of the
weld is approached.
When welding uniform thicknesses, the work angle
should be equal on all sides. When welding in the hori-
zontal position, best results are obtained by pointing the
gun upward slightly. When welding thick-to-thin joints, it
is helpful to direct the arc toward the heavier section. A
slight drag angle may help when additional penetration is
required.
Control of the Arc
Keep in mind that arc travel speed has a major effect on
bead size, penetration, and fusion. Arc voltage is also
very important to satisfactory welding. It controls sur-
face heating, bead contour, and to some degree, such de-
fects as undercutting, porosity, and weld discontinuities.
Because a long arc is smoother and quieter than a short
arc, it is frequently used at the expense of quality and
economy. The arc should be occasionally noisy for most
applications of spray arcs. The wire location should be
such as to keep the weld size and location of the weld
appropriate.
Process and Equipment Problems
You will probably experience very little difficulty in welding
with the MIG/MAG process. All the equipment in use today
is in an advanced stage of development and is dependable
Gas Metal Arc Welding Practice with Solid and Metal Core Wire: Jobs 22-J1J23 (Plate) Chapter 22 727
over a long service life. All things of a mechanical nature,
however, are subject to wear and unpredictable breakdown.
As a welder in the shop, it will be to your advantage to under-
stand thoroughly the process and the equipment that you are
working with. Study the two charts that are presented here
very carefully. Table 22-6, page 728 lists problems with the
MIG/MAG short arc process and their correction. Table 22-7,
pages 729730 lists problems with the MIG/MAG process
and equipment, their causes, and possible remedies.
Practice Jobs
Instructions for Completing
Practice Jobs
You will practice gas metal arc welding on mild steel,
aluminum, and stainless steel. Complete the practice jobs
according to the specifications given in the Job Outline,
pages 746 and 747, in the order assigned by your instruc-
tor. Before beginning each job, study the pages listed
under Text Reference in the outline.
These jobs should provide approximately 25 hours
practice, depending on your skill. In addition, practice
other forms of joints in all positions. Use various types
and sizes of filler wire and different shielding gases.
(Review pp. 693703 in Chapter 21 for information on
filler wire classifications.) Compare the spray arc and
short arc transfer. Compare solid wire to metal core. Ex-
periment with a variety of current values. Make sure that
the practice plates are properly prepared, are clean, and
have been tack welded with great care.
MIG/MAG Welding of Carbon Steel
The bulk of all welding is done on carbon steel. In prac-
tically every industry in which welding is a part of the
fabrication process, the use of MIG/MAG as the welding
process is on the increase. The process produces welds
that are of the highest quality, and the cost is lower than
with other processes. Welders find it relatively easy to
master the process, and they can consistently produce
sound welds at a high rate of speed.
Groove Welds: Jobs 22-J1 and J2 Plate up to 18 inch
thick may be groove welded with square edges with a root
opening of 0 to 116 inch. Heavier plate thicknesses of 316
and 14 inch may be welded without beveling the edges if
a 116- to 332-inch opening is provided. The bead should be
wider than the root spacing for proper fusion. Two passes,
one from each side, are usually necessary with backgoug-
ing to sound metal as required.
For code welding and when the requirements are un-
usually high, plate thicknesses from 316 to 1 inch should
 Table 22-6 Short Arc Mode of Transfer Troubleshooting

Surface Treatment
Wire-Feed System
Wire Composition
Possible

Oil, Rust, Paint

Gas Shielding3

Type Of Steel6
Torch Manip.

Travel Speed

Contact Tip5
Action

Inductance

Slag, Glass

Procedure
Extension

Arc Blow
Observed

Pool Size
Gas Type

Conduit4
Polarity1
Current
Voltage

Wind2
Fault

Slope

Fitup
Porosity, internal
Porosity, visible
Incomplete penetration +
Too much penetration +
Incomplete fusion
Wagon tracks
Cold lapping +
Cracks
Whiskers
Spatter +
Stubbing +
Blobbing
Bad starts +
Unstable arc
Effervescent puddle
Too fluid puddle
Too viscous puddle +
Crowned bead + + +
Undercutting
+
Should be DCEP, DCEN looks very similar in short arc welding.
1
Raise or increase.
Windshields are recommended for winds over 5 mi/h.
2
Lower or decrease.
Clogged nozzles, loose connections, and damaged hoses.
3
Check.
Wrong size, clogged.
4

Wrong size, damaged.

5

Rimming grades require highly deoxidized wires.

6

be beveled. A 60 single- or double-V without a root The open root joint should be run using short circuit or
face is recommended. A root opening of 0 to 116 inch pulse spray for the ferrous metals. Practice the 3G using
should be maintained. Wider root openings may be both uphill and downhill techniques on the root pass.
provided for double-V joints than for singleV joints. U-grooves should be employed on plate thicker than
In single-V grooves a backing pass from the reverse 1 inch. Root spacing between 132 and 332 inch should be
side is generally required unless the fitup is uniform. If maintained. A root face of 332 inch or less should be pro-
possible, the double-V joint should be used. Less filler vided to ensure adequate penetration. The U-groove butt
metal is needed to fill the joint, and less distortion re- joint requires less filler metal than the V-groove butt
sults when welding from both sides of the joint. Uni- joint.
form penetration can be obtained in joints having no For spray arc welding of carbon steel, an argon-oxygen
root face if the root opening is held between 0 and 332 mixture containing 1 to 5 percent oxygen is generally
inch, Fig. 22-20, page 731. recommended. The addition of oxygen produces a more

728 Chapter 22 Gas Metal Arc Welding Practice with Solid and Metal Core Wire: Jobs 22-J1J23 (Plate)
 Table 22-7 Troubleshooting: MIG/MAG Process and Equipment

Introduction
When troubleshooting gas metal arc welding process and equipment problems, it is well to isolate and classify them as soon as possible into
one of the following categories:
1. Electrical
2. Mechanical
3. Process
This eliminates much needless lost time and effort. The data collected here for your benefit discusses some of the common problems
of gas metal arc welding processes. A little thought will probably enable you to solve your particular problem through the information
provided.
The assumption of this data is that a proper welding condition has been achieved and has been used until trouble developed. In all cases of
equipment malfunction, the manufacturers recommendations should be strictly adhered to and followed.

Problem Probable Cause Possible Remedy

A.Feeder-control stops feeding
electrode wire while welding.
B.Electrode wire feeds but is not
energized. No welding arc.
1. Power source. 1. Power source.
a) Fuse blown in power source primary.
b) Control circuit fuse blown.
2. Primary line fuse blown.
3. Wire-feeder control.
a) Control relay defective.
b) Protective fuse blown.
c) Wire drive rolls misaligned.
d) Drive roll pressure too great.
e) Spindle friction too great.
f) Excess loading of drive motor.
g) Drive rolls worn; slipping.
h) Drive motor burned out.
4. Torch and casing assembly.
a) Casing liner dirty, restricted.
b) Broken or damaged casing or liner.
c) Torch trigger switch defective or
wire leads broken.
d) Contact tube orifice restricted; burn-back
of electrode.
e) Friction in torch.
1. Power source. 1. Power source.
a) Contactor plug not tight in socket.
b) Contactor control leads broken.
c) Remote-standard switch defective or in
wrong position.
d) Primary contactor coil defective.
e) Primary contactor points defective with
electronic solid-state contactor. See own-
ers manual.
f) Welding cables loose on terminals.
g) Work connection loose.
2. Wire-feeder control.
a) Contactor plug not properly seated.
b) Contact relay defective.
a) Replace fuse.
b) Replace fuse.
2. Replace fuse.
3. Wire-feeder control.
a) Replace contact relay.
b) Replace fuse. Find overload cause.
c) Realign drive rolls.
d) Loosen and readjust drive rolls.
e) Loosen and readjust nut pressure.
f) Clear restriction in drive assembly.
g) Replace drive rolls.
h) Test motor; replace if necessary.
4. Torch and casing assembly.
a) Remove liner, blow out with
compressed air.
b) Replace faulty part.
c) Replace switch; check connections.
d) Replace.
e) Check wire passage; clean, replace parts as
required.
a) Tighten plug in receptacle.
b) Repair or replace.
c) Repair or replace; position correctly.
d) Replace.
e) Replace points or contactor.
f) Have serviced by qualified technician.
g) Tighten connections.
h) Connect to work; tighten connection.
2. Wire-feeder control.
a) Tighten plug in receptacle.
b) Repair or replace.

(Continued)

Gas Metal Arc Welding Practice with Solid and Metal Core Wire: Jobs 22-J1J23 (Plate) Chapter 22 729