Gas Metal Arc

Welding (GMAW)

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Objective
GMAW Process
Machine components and setup
Power source and gas
Process parameter

.
Definition

GMAW: A semi-automatic or automatic arc welding

process
- where a continuous and consumable wire
electrode and (power) electric current.
- shielding gas are delivered to the weld through a
welding gun.

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Equipment Requirements
1 Store and deliver gas to the weld at the
correct rate.
2 Store and deliver welding wire to the weld
at the correct rate.
3 Provide correct current.
4 Automatically or semi automatically control
all the above features.

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GMAW Equipment
• Power source
• Wire feeder and controls
• Welding gun and components
• Shielding gas delivery system
• Weld cleaning and finishing tools

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 What is the function
of each part?
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 Flow meter
What is the purpose of the flow meter?

Two types of flow meters are available.

One piece: the gas flow rate is regulated by
using a fixed orifice and changing the pressure
to change the flow rate.
Two piece: the gas flow rate is adjusted by using
a constant pressure regulator and changing the
flow rate with an adjustable orifice (needle
valve).

Which type will provide better control of the gas

flow? Why?

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Consumables—Shielding Gases
Carbon dioxide
• Requires special valve
• Must use washer between valve and
flow meter.
Argon
• Same valve as helium
Mixture
• Same valve as argon

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 Wire Feeding systems
Function is to deliver the
welding wire at a constant
rate to the gun.
Three systems
Push
Pull
Push--pull

Two types
Constant speed
Voltage sensing
Two types of construction
Internal
External

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Wire Drive Systems
The drive system is responsible for pulling the wire from the
spool and then pushing the wire down the cable.
• The wire drive systems
consisted of one or more
pair of feed rolls and wire
guides.
• The guides must be the
proper size and adjusted
close to the feed rolls and
aligned with gap between
the rolls.

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 Feed Rolls
For a GMAW system to work correctly, the feed rolls
must be the correct type and size.
The feed roll tension must also be set correctly.

V Groove U Groove
Knurled V groove Cogged U groove

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GMAW Gun
H
F
D
B G
C E

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Welding Gun--cont.
Contact tube Nozzle
Sliding electrical connection.
Must match the diameter of the wire
Must be replaced frequently
The nozzle directs the shielding
gas towards the weld pool. Contact tube

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Power Supply
• GMAW and FCAW both use a constant voltage power supply.
 Many different types are available.
 Industrial rate are usually 100% duty cycle.
 Non industrial power supplies have sloping duty cycle.
 May have a built in heat sensitive overload switch.

• Install power supply so that the cooling air through the machine is not
restricted.

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Selecting Power Supply
Seven factors to consider when selecting a
GMAW or FCAW power supply.
1 Type of metal
2 Metal thickness range
3 Type of metal transfer
4 Wire diameter range
5 Primary power available
6 Capacity of power source
7 Control and adjustments

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 GMAW Processes
The GMAW process provides four different metal
transfer methods.
Short circuiting
Spray
Globular
Pulse spray

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 Pulse Spray
Transfer
In the pulse spray transfer the current alternates from the
desired welding current to a background current.
The background current just maintains the arc.
The peak current, time of peak current, background current
and time of background current are all adjustable.

A = Peak Current
B = Background Current
C = Peak Time
D = Pulses per Second

What are the advantages of the metal transfer method?

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Consumables—Welding wire
Solid (Copper clad)

Flux core

Stainless steel

Hard surfacing

Aluminum

What three wire diameters

are most popular?

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 Stickout
• An important function
of all GMAW processes
is the stickout.
• Stickout is the distance
from the end of the
contact tube to the
weld surface.

What is a potential problem of

insufficient stickout?

What is a potential problem of Excessive stickout?

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Thank you
 FCAW

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 Questions

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 Gas Metal Arc
Welding (GMAW)

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Definition
GMAW: A semi-automatic or automatic arc welding process
in which a continuous and consumable wire
electrode and a shielding gas are delivered to the
weld through a welding gun.

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 GMAW
Hazards
1 Electrical shock
2 Hot metal
3 Harmful rays
4 Hot spatter
5 Fumes
6 Shielding gas
7 Pinch points

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 Introduct
ion
GMAW has the same three requirements of all arc welding.

How does GMAW meet these requirements?

Shielding Heat Filler Material

GMAW

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 GMAW Processes
The GMAW process provides four different metal
transfer methods.
Short circuiting
Spray
Globular
Pulse spray

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 Short Circuiting
Transfer
When the gun trigger is activated, the wire starts to move toward the metal.

1. When
the wire
5. The wire touches
touches the 2. The high the metal it
metal and 4. As the wire current flow shorts out.
the process continues to 3. The current melts the end
continues move, the arc pinches off the of the wire
restarts. droplet and the arc and a droplet
stops. is formed.

 Process is recognizable by its sharp buzzing or crackling sound

 Most common method
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