GMAW Lab Slide 1 ME313 Metals Processing - Lab GMAW Lab Slide 1 Last Modified by PAN 1/25/05

Gas Metal Arc Welding

(GMAW)
ME 313 Manufacturing Processes

GMAW Lab Slide 2
ME313 Metals Processing - Lab
Process Description
Gas Metal Arc welding - process in which the heat
required for welding is generated by an arc maintained
between a consumable wire electrode and the workpiece.
A consumable electrode is feed into a weld pool
A steady stream of gas is feed to provide full protection to
the weld.
The wire feeder continuously feeds the filler wire
electrode, and the arc gap is maintained by the welding
power supply
Gas Metal Arc Welding (GMAW) a.k.a Metal Inert Gas
Welding (MIG)
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Basic Welding Gun
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ME313 Metals Processing - Lab
Heat Affected Zone

The Heat
Affected Zone (HAZ)
is the base metal that
has experienced
thermal cycling
without being melted.
This thermal cycling
causes the
microstructure to
change from that of
the surrounding
unaffected base
material.
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Power Supplies
The GMAW uses a constant voltage power supply
In order to maintain the a fixed arc gap, the rate at which
the wire melts off (current density) must be equal to the
wire feed speed.
The current density is the amount of current flowing
through the given cross section of the wire.
Current density has units of Amps / in
2
, and the units for
wire feed speed are inches per minute.
A constant voltage power supply keeps this ratio in
equilibrium.

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Volt - Amp Curve
Current
Voltage
I
o

V
o

OCV
SCC
The Volt - Amp curve is characteristic of all constant voltage
power supplies.
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Polarity
+
+
+
+
+
+
-
-
-
-
-
-
Electrode Negative Electrode Positive
Work Piece Positive Work Piece Negative
Ions
Ions
Electrons
Electrons
Straight Polarity DCSP Reverse Polarity DCRP
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Modes of Transfer
Spray Transfer - In this mode, an axial
stream of many small diameter molten
metal droplets are propelled across the arc
gap by the considerable arc forces present.
Spray transfer gives high heat input and
high deposition rate. It is generally used in
the flat and horizontal positions. Note that
true spray transfer requires at least 85 - 90%
Argon shielding gas. The high Argon
requirement also results in less spatter.
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Spray Transfer
Gas Metal-Arc Welding
Electrode Holder
Droplets
Shielding Gas
Consumable Electrode
Base Metal
Weld Puddle
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Globular Transfer
At lower current densities, transfer occurs by the
formation of a single large drop at the end of the
electrode wire. The drop grows in size until
gravity forces overcome the surface tension of the
liquid and the drop is transferred by gravity across
the arc gap. Because of the lower current density,
electromagnetic forces are much weaker and do
not play a role in the transfer process. Globular
transfer cannot be used for out of position
welding. Globular transfer can be done with all
types of shielding gases.
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Globular Transfer
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Short-Circuit Transfer
Here, the metal drop that forms on the end of the
electrode wire is transported toward the work
piece while still attached to the wire. When the
drop contacts the weld puddle, a large short-circuit
current surge detaches the drop and the arc is
restored. Short-circuit transfer permits all-position
welding with all types of shielding gases. It is
commonly used for welding thin sections
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Short Circuiting Transfer
Gas Metal-Arc Welding
Drop begins to form
Drop advances towards Base Material
Drop touches weld puddle causing
short circuit
Circuit is broken; another drop forms
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Shielding Gases

Argon (AR)
Inert gas
Low heat and giving minimum penetration
Argon costs less than Helium but more than Carbon Dioxide
Use whenever a completely inert shielding gas is required without the
need for deep penetration.

Helium (HE)
Completely inert gas
Maximum heat input and weld penetration
Most expensive option (of the three)

Carbon Dioxide (CO2)
A compound which is not fully inert.
The cheapest option (of the three)
Cannot be used on non-ferrous alloys.
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Process Advantages
higher deposition efficiency than SMAW
higher deposition rate than SMAW
reduction of smoke and fumes
may be automated
operator skill level less than that required for
SMAW
all position welding possible
wide variety of alloys weldable, including
Aluminum
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Process Disadvantages
inaccessible areas difficult to weld
feeding wire over long distances
feeding soft, small diameter wire
higher equipment and maintenance costs
incomplete shielding in drafts and wind