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ELECTRODES
D.SELVAKUMARAN SSE/AWTI
GMAW
Gas Metal Arc Welding /
Gas shielded Arc Welding
MIG MAG
Metal Inert Gas Welding Metal Active Gas Welding
VOLTAGE
20 V
ARC
VOLTAGE
CURRENT
Basic welding parameters in
GMAW
The basic parameters which require to be set in GMAW
process are
Current ( amps )
Voltage ( volts )
Shielding gas flow rate. ( litres / min )
Stick out
Torch angle
Welding speed
Basic welding parameters in
GMAW
Current ( amps )
Linked with wire speed
Matching Amount Wire pushed & burning rate
Voltage ( volts )
Less voltage gives peaked bead
More voltage spreads the bead; more flat bead
Basic welding parameters in GMAW
Shielding Gas
shields the arc and molten weld pool
stabilizes the arc
allows smooth transfer of metal
Basic welding parameters in
GMAW
The primary shielding gasses used are:
Argon
co2
Argon - 1 to 5% Oxygen
Argon - 3 to 25% CO2
Argon/Helium
Basic welding parameters in
GMAW
Shielding gas flow rate
Required to prevent oxidation
Low & high flow rate results in porosity
Should be matched with deposition rate
Basic welding parameters in
GMAW
Stick out
Longer stick out reduces penetration
Longer stick out increases dposition
For Higher parameter (V,I) more stick out
Mode of metal transfer
Short circuiting transfer
Globular transfer
Spray transfer
Short circuiting / Dip transfer
Short circuiting transfer
0.8 50 150
If the wire feed speed is too high the wire will not be melted fast
enough and will pass through the arc hitting the plate, which is
known as stubbing. The resultant weld is peaky with little fusion
and a lot of spatter.
Selection of Arc Voltage
Factors to be considered:
• Wire speed/Current
• Mode of metal transfer
• Shielding gas
• Stand - off distance
Empirical relationships:
V = 14 + (0.04 x I ) For short arc
V = 16 + (0.04 x I ) For spray arc
Self-regulation of the arc
Constant voltage or
potential power sources
The current adjusts itself to 20 V
burn off rate ARC
for a small change in arc VOLTAGE
length there is a large
change in welding current
which makes it quite
sensitive and helps in CURRENT
maintaining a steady arc
length which gives
consistent quality welds.
This is called self-
regulation of the arc length
and is a requirement for
success of GMAW welding.
MIG Welding Problems
ER70S-6MNHZ
Electrode
Rod
UTS
S- solid wire
70X000
Psi C- composite
2 – 6 Chemical
Composition
GS – single pass
M – Argon + CO2 or
only
C – CO2
N – Nuclear application
HZ – hydrogen designator
H16 means 16ml/100g of deposit
Classification of Carbon steel consumable
electrode wires meant for CO2 welding
applications [ AWS A5.18 ]
E70S-6
E - electrode wire
70 - UTS
S - Solid wire
6 - Chemical composition of the wire
Chemical Composition filler wire in weight %
(Wire: ER 70S6 AWS A5.18)
C: 0.07-0.15
Mn: 1.4-1.8
Si: 0.8-1.15
S: 0.035
P: 0.025
SPECIFICATION BARE STAINLESS STEEL
WELDING ELECTRODES AND RODS
(AWS 5.9)
AWS A 5.9 : Solid wire electrode or rods for GMAW or SAW or
others
Classification based on Composition, alloying elements
CLASSIFICATION OF ELECTRODES FOR GMAW - Stainless Steel
(AWS 5.9)
ER309L
Electrode
Rod
Chemical composition/
Grades of filler metal
L – low carbon
Si, Mo, Nb – alloying
element
IRS M46
Flux Cored Arc Welding (FCAW)
Flux Cored Arc Welding (FCAW)
Flux cored arc welding (FCAW):
•electrode is a continuous, consumable, tubular containing flux.
•The flux provides
•alloying
•arc stability
•slag cover
•de-oxidation
•gas shielding with some wires.
•The area of the flux cored wire is much smaller that than that of
a solid MIG wire. This means that the electrical resistance of
the flux cored wire is higher than with solid MIG wires (for same
wire size)
FCAW
Self-shielded FCAW:
•arc shielding provided by the flux core.
•Basic type flux
Gas shielded FCAW:
•Shielding by externally supplied
gases.
•hybrid of SMAW and GMAW
•basic or rutile flux
Advantages
High deposition rates
Deeper penetration
than SMAW
High-quality
Less pre-cleaning than
GMAW
out-of-position welds
Self-shielded FCAW is
draft tolerant.
Low alloy steel FCAW Electrode
Classification AWS A5.29
E81 T1 – W2
Electrode
Minimum UTS usability Weathering
80,000 psi steel
0 – Flat, Horizontal Type Gas, Usability
1 – all position and Performance
Flux Cored /Tubular
C – CO2
Electrode
3 - ‘no gas
M – ACM
‘ ‘ - Self shielded
STAINLESS STEEL FCAW Electrode
Classification AWS A5.22
E309 T1 - 1
Electrode
Position Type Gas, Usability
0- F,H
Chemical composition and Performance
1- all
1 – CO2
3 - ‘no gas
Flux Cored /Tubular 4 – ACM
Electrode 5 – 100% Argon (TIG)
G – not specified