Gas Metal Arc Welding

INDIABULLS

What Is GMAW ?
A Fusion Welding Process Semi Automatic Arc Between Consumable Electrode &Work Arc Generated by Electric Energy From a Rectifier / Thyrester / Inverter Filler Metal As Electrode Continuously fed From Layer Wound Spool. Filler Wire Driven to Arc By Wire Feeder through Welding Torch Arc & Molten Pool Shielded by Inert Gas through Torch / Nozzle
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Gas Metal Arc Welding

MIG Shielding Gas Ar / Ar + O2 / Ar + Co2 MAG Shielding Gas Co2 FCAW Shielding Gas Co2 With Flux cored Wire Note:- Addition of 1 5% of O2 or 5 10% of Co2 in Ar. increases wetting action of molten metal
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Power Source For MIG / MAG

Inverter- DC Thyrester DC Motor Generator DC Rectifier DC

Characteristic Of GMAW Power Source

Constant V / Linier Characteristic
V

Appx. Horizontal Curve

V1 V2

A1

A2

A
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Current & Polarity

DC- Electrode +Ve
Stable Arc Smooth Metal Transfer Relatively Low Spatter Good Weld Bead Characteristics

DC- Electrode Ve, Seldom Used AC- Commercially Not In use

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Accessories Of GMAW

Power Source Wire Feed Unit Shielding Gas Cylinder, Pressure gauges/ Regulator, Flow meter ( Heater For Co2 ) Welding Torch Water Cooling System (For Water cooled Torch) Earthing Cable With Clam

Tools For GMAW

Head Screen With DIN 13 / 14 Dark Glass Hand Wire Brush / Grinder With Wire Wheel Cutting Pliers Hand Gloves Chipping Hammer / Chisel & hammer Spanner Set Cylinder Key Anti-spatter Spray Earthing Cable With Clamp
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GMAW Torch
On / Off Switch

Shielding Gas Spring Conduit

Torch Handle

Gas Cup Arc

Nozzle Tip Filler Wire - Electrode Job

Equipment & Accessories

Pressure Regulator Flow Meter Shielding Gas Switch Solenoid Valve

Heater (Only For Co2) Shielding Gas Cylinder

Copper Cup Electrode / Wire Arc

Welding Torch Wire Inside Spring Lining Contact Tip Argon / Co2 Shielding Work

Wire Feeder Wire Spool

Power Source With Inductance

Torch With Cable Max. 3Mtr

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Types Of Wire Feeding In GMAW

Push Type
Wire fed in to The torch by Pushing through Flexible Conduit From A Remote Spool

Pull Type
Feed Rollers Mounted on The Torch Handle Pulls the Wire From A Remote spool

Self Contained
Wire Feeder & The Spool On the Torch

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Function Of Shielding Gas In GMAW

Prevents Air contamination of weld Pool Prevents Contamination During Metal Transfer Increases fluidity of molten metal Minimizes the spatter generation Helps in even & uniform bead finish

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Shielding Gases For GMAW

MIG: Argon Or Helium For SS, CS, LAS & Non-ferrous Mt & Al MIG: Ar + 1 to 2 % O2, Wire With Add. Mn & Si For SS, CS, LAS & Non-ferrous Mt & Al MIG: Ar + 5 to 20 % Co2 Wire With Add. Mn & Si For SS, CS, LAS & Non-ferrous Mt & Al MAG: Co2 With Solid Wire For CS & LAS FCAW: Co2 With Flux Cored Wire For CS, LAS & SS Overlay
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ASME Classification For CS GMAW Wire

SFA 5.18 : - CS Solid Wire ER 70 S 2, ER 70 S 3 ER 70 S 6, ER 70 S 7 SFA 5.20 :- CS Flux Cored Wire E 71 T-1, E 71 T-2 ( Co2 Gas ) E 71 T-1M, E 71 T-2M ( Ar + Co2 Mix)

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GMAW CS Wire
Generally Copper Coated
Prevents Oxidation / rusting in Storage Promotes Electric Conductivity in Arcing

Available In Solid & Flux Cored

Size in mm 0.8, 1, 1.2, 1.6, 2, 2.4, 3

Manganese & Silicon ( Mn 1 2 %, Si Max 1%)

Act As Deoxidizing Agents Eliminate Porosity Increase Wetting Of Molten Pool
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Metal Transfer In MIG

Short-Circuiting / Dip Transfer
Globular Transfer Spray Transfer

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Metal Transfer In MIG

Up to 120A
14 22V CS Solid Wire 1.2 mm 120 to 250A Above230A

16 24 V

24 35 V

Dip/Short Circuiting Co2 or Ar

Globular Co2 or Ar

Spray Only Ar / Ar+O2

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Short-Circuiting / Dip Transfer

Wire In Contact With Molten Pool 20 to 200 times per Second Operates in Low Amps & Volts Less Deposition Best Suitable for Out of Position Welding Suitable for Welding Thin Sheets Relatively Large opening of Root Can be Welded Less Distortion Best Suitable for Tacking in Set up Prone to Get Lack of Fusion in Between Beads
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Globular Transfer
Metal transferred in droplets of Size grater than wire diameter Operates in Moderate Amps & Volts Better Deposition Common in Co2 Flux Cored and Solid Wire Suitable for General purpose Welding

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Spray Transfer
Metal transferred in multiples of small droplets 100 to 1000 Droplets per Second Metal Spray Axially Directed Electrode Tip Remains pointed Applicable Only With Inert Gas Shielding Not With Co2 Operates in Higher Amps & Volts Higher Deposition Rate Not Suitable for Welding in Out of Position. Suitable for Welding Deep Grooves
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Pulsed Spray Welding

Power Source Provides Two different Current LevelsBackground and Peakat regular interval Background & Peak are above and below the Average Current Best Suitable for Full Penetration Open Root Pass Welding Good Control on Bead Shape and Finish
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Synergic Pulse GMAW

Parameters of Pulsed Current (Frequency, Amplitude, Duration, Background Current) Related to Wire feed Rate One Droplet detaches with each pulse An Electronic Control unit synchronizes wire feed Rate with Pulse Parameters Best Suitable for Most Critical Full Penetration Open Root Pass Welding Good Control on Open Root penetration, Bead Shape and Finish
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GMAW Process Variables

Current Voltage Travel Speed Stick Out / Electrode Extension Electrode Inclination Electrode Size Shielding Gas & Flow Rate Welding Position
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Parameter For 1.2 FC Wire

Current 200 to 240 A Voltage 22-24 Travel Speed 150 to 250 mm / min Stick Out / Electrode Extension 15 to 20 mm Electrode Inclination Back Hand Technique Shielding Gas Co2, 12 L/Hr

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Parameter For 1.2 Solid Wire

Current 180 to 220 A Voltage 20-22 Travel Speed 150 to 200 mm / min Stick Out / Electrode Extension 10 to 20 mm Electrode Inclination Back Hand Technique Shielding Gas Co2 12 L/Hr

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Results In Change Of Parameters

Increase In Current More deposition, More Penetration, More BM Fusion Increase In Voltage More Weld Bead Width, Less Penetration, Less Reinforcement, Excess Spatter Increase In Travel Speed Decrease in Penetration, Decrease in Bead Width, Decrease In Gas Flow rate Results In porosity Long Stick Out / Electrode Extension Excess Weld Deposit With Less Arc intensity, Poor Bead Finish, Shallow Penetration
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Common Defects In GMAW

1. Porosity 3. Lack Of Fusion 5. Over Lap 7. Crack 9. Burn Through 11. Unstable Arc 2. Spatters 4. Under Cut 6. Slag 8. Lack Of Penetration 10. Convex Bead 12. Wire Stubbing

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Porosity
Cause
1) Less Mn & Si In Wire 2) Rusted / Unclean BM / Groove 3) Rusted wire 4) Inadequate Shielding Gas

Remedy
1) Use High Mn & Si Wire 2) Clean & warm the BM 3) Replace the Wire 4) Check & Correct Flow Rate

Porosity

. .

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Spatters
Cause
1) Low Voltage 2) Inadequate Inductance 3) Rusted BM surface 4) Rusted Core wire 5) Quality Of Gas

Remedy
1) Increase Voltage 2) Increase Inductance 3) Clean BM surface 4) Replace By Rust Free wire 5) Change Over To Ar + Co2

Spatters

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Lack Of Fusion
Cause 1) Inadequate Current
2) Inadequate Voltage 3) Wrong Polarity 4) Slow Travel Speed 5) Excessive Oxide On Joint Lack Of Fusion

Remedy 1) Use Right Current

2) Use Right Voltage 3) Connect Ele. + Ve 4) Increase Travel speed 5) Clean Weld Joint

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Undercut
Cause 1) Excess Voltage 2) Excess Current 3) Improper Torch angle 4) Excess Travel Speed
Under cut

Remedy 1) Reduce Voltage 2) Reduce Current 3) Train & Qualify the Welder 4) Reduce Travel Speed

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Overlap
Cause 1) Too Long Stick Out 2) Inadequate Voltage
Overlap

Remedy 1) Reduce Stick Out 2) Increase the Voltage

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Slag
Cause 1) Inadequate Cleaning 2) Inadequate Current 3) Wrong Torch angle 4) Improper bead placement Remedy 1) Clean each bead 2) Use Right Current 3) Train / Qualify welder 4) Train / Qualify Welder

Slag

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Crack
Cause Remedy
1) Incorrect Wire Chemistry 1) Use Right Wire 2) Increase wire Feed 2) Too Small Weld Bead 3) Preheat Uniformly 3) Improper Preheat 4) Post heating or ISR 4) Excessive Restrain

crack

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Lack Of Penetration*
Cause 1) Too Narrow Groove Angle 2) Inadequate Root opening 3) Too Low Welding current 4) Wrong Torch angle 5) Puddle Roll In Front Of Arc 6) Long Stick Out
* Applicable to SSFPW

Remedy 1) Widen The Groove 2) Increase Root Opening 3) Increase Current 4) Train / Qualify Welder 5) Correct Torch Angle 6) Reduce Stick Out

LOP

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Burn through*
Cause 1) Excess Current 2) Excess Root opening 3) Inadequate Root face 4) Too Low Travel Speed 5) Quality Of Gas Remedy 1) Reduce the Current 2) Reduce root opening 3) Increase root face 4) Increase Speed 5) Use Ar + Co2
*Applicable to root pass

Burn trough

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Convex Bead Finish

Cause 1) Low Current 2) Low Voltage 3) Low Travel Speed 4) Low Inductance 5) Too Narrow Groove
Uneven bead finish

Remedy 1) Increase Current 2) Increase Voltage 3) Increase Travel Speed 4) Increase Inductance 5) Increase Groove Width

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Unstable arc
Cause 1) Improper Wire Feed 2) Improper Gas Flow 3) Twisted Torch Conduit Remedy 1) Check Wire Feeder 2) Check Flow Meter 3) Straighten Torch Cab

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Wire Stubbing
Cause 1) Too Low Voltage 2) Too High Inductance 3) Excess Slope 4) Too Long Stick Out Remedy 1) Increase Voltage 2) Reduce Inductance 3) Adjust Slope 4) Reduce Stick Out

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Important Terminology used in Critical Welding

Preheating Post Heating or Dehydrogenation Intermediate Stress leaving Inter pass Temperature Post Weld Heat Treatment

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What Is Preheating?
Heating the base metal along the weld joint to a predetermined minimum temperature immediately before starting the weld. Heating by Oxy fuel flame or electric resistant coil Heating from opposite side of welding wherever possible Temperature to be verified by thermo chalks prior to starting the weld
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Why Preheating?
Preheating eliminates possible cracking of weld and HAZ Applicable to Hardenable low alloy steels of all thickness Carbon steels of thickness above 25 mm. Restrained welds of all thickness Preheating temperature vary from 75C to 200C depending on hardenability of material, thickness & joint restrain
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How does Preheating Eliminate Crack?

Preheating promotes slow cooling of weld and HAZ Slow cooling softens or prevents hardening of weld and HAZ Soft material not prone to crack even in restrained condition

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What Is Post Heating?

Raising the pre heating temperature of the weld joint to a predetermined temperature range (250 C to 350 C) for a minimum period of time (3 Hrs) before the weld cools down to room temperature. Post heating performed when welding is completed or terminated any time in between. Heating by Oxy fuel flame or electric resistant coil Heating from opposite side of welding wherever possible Temperature verified by thermo chalks during the period

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Why Post Heating?

Post heating eliminates possible delayed cracking of weld and HAZ Applicable to Thicker hardenable low alloy steels Restrained hardenable welds of all thickness Post heating temperature and duration depends on hardenability of material, thickness & joint restrain
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How does Post Heating Eliminate Crack?

SMAW introduces hydrogen in weld metal Entrapped hydrogen in weld metal induces delayed cracks unless removed before cooling to room temperature Retaining the weld at a higher temperature for a longer duration allows the hydrogen to come out of weld

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What Is Intermediate Stress Relieving?

Heat treating a subassembly in a furnace to a predetermined cycle immediately on completion of critical restrained weld joint / joints without allowing the welds to go down the pre heat temperature. Rate of heating, Soaking temperature, Soaking time and rate of cooling depends on material quality and thickness Applicable to Highly restrained air hardenable material
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Why Intermediate Stress Relieving?

Restrained welds in air hardenable steel highly prone to crack on cooling to room temperature.

Cracks due to entrapped hydrogen and built in stress

Intermediate stress relieving relieves built in stresses and entrapped hydrogen making the joint free from crack prone
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What Is Inter- Pass Temperature?

The temperature of a previously layed weld bead immediately before depositing the next bead over it Temperature to be verified by thermo chalk prior to starting next bead Applicable to Stainless Steel Carbon Steel & LAS with minimum impact
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Why Inter Pass Temperature?

Control on inter pass temperature avoids over heating, there by Refines the weld metal with fine grains Improves the notch toughness properties Minimize the loss of alloying elements in welds Reduces the distortion

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What Is Post Weld Heat Treatment?

Heat treating an assembly on completion of all applicable welding, in an enclosed furnace with controlled heating/cooling rate and soaking at a specific temperature for a specific time. Rate of heating, Soaking temperature, Soaking time and rate of cooling depends on material quality and thickness Applicable to All type of CS & LAS
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Why Post Weld Heat Treatment?

Welded joints retain internal stresses within the structure HAZ of welds remains invariably hardened Post Weld Heat Treatment relieves internal stresses and softens HAZ. This reduces the cracking tendency of the equipment in service

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Thanks

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