GMAW & FCAW

Arc welding processes

Weld Metal Deposited By Major Arc

Welding Processes

Developed

India

Countries

GMAW
Introduction
Fundamentals
Advantages
Limitations

Principles of Operation
Metal transfer modes

Equipment
Welding gun & accessories
Wire feed unit
Power supply & welding
controls
GMAW automation

Materials & Consumables

Electrodes
Shielding gases

Process Variables
Weld Joint Designs
Inspection & Weld quality
Quality concerns
Weld Discontinuities

Summary

Gas metal arc welding

Gas metal arc
welding
(GMAW), is
sometimes
referred to as
Metal inert gas
(MIG) welding or
Metal active gas
(MAG) welding

Gas metal arc welding

GMAW is a semi-automatic or automatic
arc welding process in which a continuous
and consumable wire electrode and a
shielding gas are fed through a welding
gun.
A constant voltage, direct current power
source is most commonly used with
GMAW.
5

GMAW - Operation

Applications
Wide variety of applications in Industrial
manufacturing, agriculture, construction,
shipbuilding, mining & automotive
industries
GMAW Process is used for welding of
pipes, pressure vessels, structures, steel
components, furniture, automotive
components and numerous other products
7

GMAW Equipment - Schematic

1. Welding torch
2. Workpiece

3. Power source
4. Wire feed unit
5. Electrode
source

6
3

6. Shielding gas
supply

Power Source Characteristics

Power Sources of Constant Current type having

drooping characteristics are used for

- MMAW process
- GTAW process
- Plasma processes

Power sources of constant voltage type having flat

characteristics are used for

- GMAW & FCAW processes
- SAW process

V-A relationship drooping

10

V-A Relationship CV power

source (GMAW / SAW)

11

Calculation of the Slope for a Power Source

12

Automatic arc length regulation

13

GMAW Equipment

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4 wheel wire drive unit

15

Wire Feed Speed / Current.

Constant potential power sources are used for
GMAW and have no built in means of changing the
current. The current adjusts itself to burn off the
quantity of wire delivered. If the wire feed speed is
increased more current is drawn to burn it off . In
this way adjusting the wire feed speed also adjusts
the current supplied.

The current dictates the amount of heat generated

by the arc. Increasing the current increases the arc
energy and therefore the heat input. This in turn
increases fusion and penetration, wire deposition
rate and travel speed.
16

GMAW Equipment - Welding Gun

GMAW Welding Gun

1. Handle
2. Moulded phenolic
insulation (shown in
white)
3. and threaded metal
nut insert (yellow)
4. Shielding gas nozzle
5. Contact tip
6. Nozzle

17

Arc Welding Gun Nomenclature

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Advantages
Efficient process to weld all commercial
metals & alloys in all positions
Deposition rates are significantly higher
than SMAW
Long welds - without stops and starts
Deep penetration welds are possible using
spray transfer to weld smaller fillet welds
Minimal post weld cleaning required due
to absence of heavy slag
19

Limitations
Welding equipment is more complex,
costly and less portable
Difficult to use in hard-to-reach places
since the gun is larger than a stick
electrode holder.
Welding arc needs to be protected against
air drafts (of 8 Km/h)

20

GMAW Operation: WELD AREA

1. Direction of
travel
2. Contact tube
3. Electrode
4. Shielding gas
5. Molten weld
metal
6. Solidified weld
metal
7. Workpiece
21

GMAW Metal Transfer Modes

There are four primary methods of metal
transfer in GMAW. They are:
Globular
Short-circuiting
Spray, and
Pulsed-spray

Each transfer mode has distinct

properties, advantages and limitations.
22

Modes of transfer
The mode of transfer is determined by a
number of factors:
Magnitude, type and polarity of welding
current
Electrode diameter
Electrode composition
Electrode extension and
Shielding gas composition
23

Influence of welding current & gas on

metal transfer mode in GMAW
DIP

CO2 /

GLOBULAR

CO2

SPRAY

Argon Mix

Ar Mix

24

GMAW Metal Transfers

Spray Transfer

Globular Transfer

4 steps in
Short
circuiting
transfer

25

Short Circuit Transfer

occurs when carbon dioxide is the shielding gas,
the electrode diameter is smaller, and the
current density is low.
The metal is transferred from the electrode only
during the period in which the electrode is in
contact with the weld pool.
No metal is transferred across the arc.
The electrode contacts the weld pool in the
range of 20- to 200 times per second.
26

Short Circuit Transfer

Molten droplets forms on the tip of the electrode,
but instead of dropping to the weld pool, they
bridge the gap between the electrode and the
weld pool as a result of the greater wire feed
rate.
This causes a short circuit and extinguishes the
arc, but it is quickly reignited after the surface
tension of the weld pool pulls the molten metal
bead off the electrode tip.
This process is repeated 20 to 200 times per
second, making the arc appear constant to the
human eye.
27

As a result of the lower current, the heat

input for the short-arc variation is reduced,
making it possible to weld thinner
materials while decreasing the amount of
distortion and residual stress in the weld
area.
This transfer is generally suited for joining
of thin sections, for out-of-position welding
and bridging large root openings
28

This type of metal transfer is slow and it is

difficult to maintain a stable arc, because it
depends on achieving a consistent and
high short-circuiting frequency, which can
only be accomplished with a good power
source, suitable welding conditions, and
significant welder skill.

29

Globular Transfer
GMAW with globular metal transfer is often
considered the most undesirable of the four
major GMAW variations,
because of its tendency to produce high heat,
a poor weld surface, and spatter.
The method was originally developed as a cost
efficient way to weld steel using GMAW,
because this variation uses carbon dioxide, a
less expensive shielding gas than Argon.
30

Globular transfer
As the weld is made, a ball of molten metal from
the electrode tends to build up on the end of the
electrode, often in irregular shapes with a larger
diameter than the electrode itself.
When the droplet finally detaches either by
gravity or short circuiting, it falls to the workpiece,
leaving an uneven surface and often causing
spatter.
As a result of the large molten droplet, this mode
of transfer is generally limited to flat and
horizontal welding positions.
31

Spray Transfer
Spray transfer GMAW occurs when the molten
metal from the electrode is propelled axially
across the arc in the form of minute droplets.
With Argon-rich gas shielding it is possible to
produce a very stable, spatter-free axial spray
transfer mode.
The mode requires Direct current with a positive
electrode (DCEP) and a current level above a
critical value termed the spray transition current.
Below this level, the transfer is globular.
32

In this variation, molten metal droplets are

rapidly passed along the stable electric arc
from the electrode to the workpiece,
essentially eliminating spatter and
resulting in a high-quality weld finish.
However, high amounts of voltage and
current are necessary, which means that
the process involves high heat input and a
large weld area and heat-affected zone.
33

Axial Spray Transfer

Molten metal is
propelled axially
across the arc in
minute droplets
Argon-rich gas
shielding produces
stable spatter free
axial spray transfer
mode
34

Modes Of Metal Transfer

DIP TRANSFER
Low current - low voltage used to produce
short circuiting arc, freq. 200 times / minute.
Used for sheet metal and postional welding
SPRAY TRANSFER
Higher currents and voltage used , droplet size
same as or lower than the wire diameter.
Higher deposition rate penetration and fluidity
of the molten pool , increases the productivity
35

Modes Of Metal Transfer

Contd.

GLOBULAR TRANSFER
An intermediate stage between dip and spray
transfer . droplet sizes are more than the wire dia .
Produces excessive spatter and erratic arc
behaviour
PULSED TRANSFER
Controlled method of spray transfer. Heat input to
the job is controlled by low background current
with high pulses using special type of equipment
36

Pulse Transfer

Combines the control on heat input of short arc with the higher
deposition rate of open arc.
Gives extremely precise control on metal transfer and penetration
to give superior weld quality
In synergic pulsed systems wire feed rate synchronised with
pulsed current to control individual droplet detachment.
37

Shielding Gases
Shielding gases provide a
protection to the weld metal
from the atmosphere and
have a pronounced effect on:
Arc characteristics
Mode of metal transfer
Penetration and weld bead profile
Speed of welding
Undercutting tendency
Cleaning action
Weld metal mechanical properties

Types of shielding
gases used in GMAW
Carbon Dioxide (CO2)
Argon
Helium
Oxygen
Mixtures of the above
gases

38

Shielding Gas
The choice of a shielding gas depends on
several factors, most importantly:
the type of material being welded and
the process variation being used

39

Shielding Gas
Shielding gases are necessary for gas
metal arc welding to protect the welding
area from atmospheric gases such as
nitrogen and oxygen, which can cause
fusion defects, porosity, and weld metal
embrittlement if they come in contact with
the electrode, the arc, or the welding
metal.
40

Shielding Gas
Pure carbon dioxide, on the other hand,
allows for deep penetration welds but;
Encourages oxide formation, which adversely
affects the mechanical properties of the weld

Its low cost makes it an attractive choice,

but
the arc is harsh, spatter is unavoidable,
making welding thin materials difficult
41

Shielding Gas
Therefore, Ar & CO2 are mixed in a 75%/25% or
80%/20% mixture, which reduces spatter and
makes it possible to weld thin steel workpieces.
Ar is also commonly mixed with other gases,
such as oxygen, helium, hydrogen, and nitrogen.
Addition of up to 5% oxygen encourages spray
transfer, which is critical for spray-arc and pulsed
spray-arc GMAW.
An argon-helium mixture is completely inert, and
is used on nonferrous materials.
42

GMAW Process- Shielding Gas

Pure inert gases such as argon and
helium
are only used for nonferrous welding;
with steel they cause
an erratic arc and encourage spatter (Helium) or
do not provide adequate weld penetration (argon)

43

Problems of using CO2 as

Shielding Gas
Unstable arc with high level of spatter
High fume formation rate
Higher level of reinforcement
Reduced speed due to high viscosity
Undercut / sharp notch at the toe of weld
44

Spatter generated
1 metre of weld at 260 amps
using 1.2mm dia. A18 solid wire

Carbon dioxide
17.1 g

Argon - 20 CO2
8.6 g

Argon-12 CO2
5.5 g
T-GK 3 (10)

Argon Mixed Gas Spray Transfer

Problems in using pure Argon

as Shielding gas
Stable and Soft arc with a tendency to wander
Finger shaped penetration profile
Poor fusion and penetration due to low heat
input
Comparatively high bead profile
47

Finger Profile of pure Argon arc

Oxygen

Pure Argon Profile

Carbon di-oxide

20%

10%

Modified by oxygen and CO2

48

Argon - Helium Mixtures used for

Aluminium and Non-ferrous metals
Helium

Argon

49

Effect of CO2 and O2 on welding speed

( 4mm throat fillet on 6mm plate)

50

CO2 and Argon mixture profiles

CO2

Argon mixture
51

Effect of shielding gases

Argon

Argon-Helium

Helium

CO2

Bead Contour & Penetration Patterns for

various Shielding Gases

52

Shielding gas profiles &

effect on weld length
weld length
1.2 m

weld length
1.15 m

Ar-CO2-O2

weld length
1m

Ar-CO2

CO2

53

Relative Effect of Oxygen versus Carbon Dioxide

additions to the shielding gas mixture

ARGON-OXYGEN

ARGON-CARBON DIOXIDE

CARBON DIOXIDE

54

Gas Flow
The desirable rate of gas flow depends
primarily
on weld geometry, speed, current, the type of
gas, and the metal transfer mode being
utilized

Welding flat surfaces requires

higher flow than welding grooved materials,
since the gas is dispersed more quickly.
55

Gas Flow
Faster welding speeds mean
that more gas must be supplied to provide
adequate coverage.

Higher current requires

greater flow, and generally, more helium is
required to provide adequate coverage than
argon.

56

Gas Flow
Metal Transfer Mode

Gas Flow required

Short circuiting & Pulsed 10 L/min (20 ft/h)

spray modes (small weld
pools)
Globular transfer

15 L/min (30 ft/h) is

preferred

Spray transfer (higher

heat input, larger weld
pool)

20-25 L/min (4050 ft/h)

57

Process Variations
Pulsed gas metal arc welding offers
Reduced spatter levels compared to short
circuiting transfer, thereby increasing
deposition rate and minimizing post weld
cleaning
Generates lower fume levels
Provides more controlled heat input resulting
in less distortion, results in avoiding
incomplete fusion & can weld sensitive
materials
58

Process Variables
Welding amperage
Polarity
Arc voltage
Travel speed
Electrode extension and stick out
Electrode orientation
Weld joint position
Electrode diameter
Shielding gas and gas flow rate
59

Summary: GMAW Benefits

GMAW is an efficient process that can be used to weld
all commercial metals and alloys
GMAW can perform in all positions, a capability
submerged arc welding does not have
Deposition rates are significantly higher that SMAW
Long welds can be deposited and the process can be
easily mechanized
Minimal post-weld cleaning is required due to absence of
slag
It is a low hydrogen process, making it a good choice of
process to be used for susceptible materials
Process skills are readily taught and acquired
60

Summary: GMAW Limitations

The equipment required for GMAW is more
complex, expensive and less portable than that
used for SMAW
Difficult to use in hard-to reach places due to the
limitation imposed by the gun size
The arc must be protected against drafts in
excess of 8 km/h, which may disperse the
shielding gas, thus limiting outdoor applications
Relatively high levels of radiated heat and arc
intensity
61

FLUX CORED
ARC
WELDING
62

Flux Cored Welding

Flux Cored Arc Welding (FCAW) is frequently
referred to as flux cored welding.
Flux cored welding is a commonly used high
deposition rate welding process that adds the
benefits of flux to the welding simplicity of MIG
welding.
As in MIG, welding wire is continuously fed from
a spool. Flux cored welding is therefore referred
to as a semiautomatic welding process.
63

64

Flux/metal-cored wires
Flux powder
consists of Ferroalloys, and/or gas
formers and/or slag
formers

Slag
consists of
silicates and
oxides

Strip (0.6 mm thick) of

carbon steel/ stainless
steel/Nickel/ copper

Resultant weld metal

contains transferred
metal, alloying
elements

65

Flux/metal-cored wires
Flux powder
consists of
Ferro-alloys
Gas formers
Slag formers

Gas shielded cored wires

contain only slag formers
and no gas formers as gas is
externally provided
Open arc (Gasless) cored
wires contain gas formers
& slag formers
Submerged arc cored
wires contain no gas
formers and no slag formers
66

FCAW
Weld
Profile

67

FCAW Advantages
High quality weld metal deposit
Excellent weld appearance
Welds many steels in a wide thickness range
High operating factor and easily mechanized
High deposition rate (up to 4 times greater than SMAW
and high current density
Relatively high electrode deposition efficiency
Requires less pre-cleaning than GMAW
Good fusion, less distortion and high tolerance for
contaminations
Good resistance to under-bead cracking
68

FCAW Limitations
Limited to welding ferrous metals and nickel
base alloys only
It produces a slag covering that must be
removed
FCAW wire is more expensive on weight basis
that solid electrodes
The equipment is more expensive, complex
The power source and wire feeder must remain
close to point of welding
More smoke and fumes than GMAW and SAW
69

Gas Metal Arc Brazing

A copper based electrode (e.g. aluminium
bronze or silicon bronze) is used instead
of a steel electrode to join steel.
As the copper alloy has a lower melting
temperature than steel, less heating of the
base metal is required in order to deposit
a weld bead, and little or no melting of the
base metal occurs.
70

The lower heat input reduces the amount

of coating that is melted away and the
copper based weld bead furnishes better
corrosion resistance than that provided by
a carbon steel weld bead.

71

Mig Brazing
Because of the low heat input, braze
welding is some times used to join heat
sensitive materials such as cast iron, for
welding of thin sheet steel to help prevent
melt through.
Gas metal arc brazing is also used to join
galvanized steels.

72

Thank you
Thanks to IIW & MSME

73