13 Gmaw

CSWIP 3.
1 Welding Inspection
TWI Training & Examination Services

Course Reference WIS 5
Course notes section reference 13
Copyright TWI Ltd 2008
Gas Metal Arc Welding

Metal Inert Gas
Metal Active Gas

The MIG/MAG welding process was initially developed in the
USA in the late 1940s for the welding of aluminum alloys.
The latest EN Welding Standards now refer the process by the
American term GMAW (Gas Metal Arc Welding)
The process uses a continuously fed wire electrode
The process is classified as a semi-automatic welding

process but may be fully automated
The wire electrode can be either bare/solid wire or flux
cored hollow wire
The weld pool is protected by a separately supplied

shielding gas
MIG/MAG - Principle of operation

PROCESS CHARACTERISTICS
Requires a constant voltage power source, gas supply, wire
feeder, welding torch/gun and hose package
Wire is fed continuously through the conduit and is burnt-off
at a rate that maintains a constant arc length/arc voltage
Wire burn-off rate is directly related to current

When the welder holds the welding gun the process is said
to be a semi-automatic process
The process can be mechanised and also automated
In Europe the process is usually called MIG or MAG
Wire feed speed is directly related to burn-off rate
Equipment for MIG/MAG
Internal wire
feed system
Transformer/
Rectifier
Power cable &

hose
assembly
Power control
panel
15kg wire spool
Power return
cable
Liner for wire

Welding gun
assembly
External wire
feed unit
MIG/MAG wire drive system

Plain top roller
Half grooved
bottom roller
Internal wire
drive system
Wire guide
Types of wire drive systems:
2 roll wire drive
4 roll wire drive

Types of drive rolls
recommended for softer

wires (aluminium)
recommended for steel

wires
Close wound
stainless
steel spring
wire liner
Teflon
liner
MIG/MAG welding gun types
Push-pull type
Goose neck type
MIG/MAG welding gun assembly

Welding gun assembly
(less nozzle)
Welding gun body

On/Off switch
Spatter
protection
Nozzles or
shrouds
Gas diffuser
Hose
port
Spot welding
spacer
Contact tips
MIG/MAG welding gun assembly

The Push-Pull gun
Contact
tip
Gas
diffuser
Trigger
Gas
nozzle
WFS remote
control
potentiometer
Union nut
ARC CHARACTERISTICS
Constant Voltage Characteristic
OCV
Large arc gap
Small change in voltage =

large change in
amperage
The self
adjusting arc.
Volts
Amps
Small arc gap
MAG Welding Variable Parameters

Wire feed speed:
Increasing the wire feed speed automatically increases the
current in the wire
The voltage is the most important setting in the spray transfer

mode, as it controls the arc length. In dip transfer it controls
the rise in current
Current:
The current is automatically increased as the wire feed is
increased. Current mainly affects penetration
Voltage:

Inductance:
Applicable to MIG/MAG process in dip transfer mode.
The inclusion or the choke in the welding circuit controls the

rate at which the current rises so that the electrode tip is
melted uniformly without excessive spatter
The electrode is fed slowly through the arc until it touches the
weld pool, at this point the output from the power supply is
short circuited and a very high current flows through the
electrode. If this was allowed to continue, the wire would melt
and eject excessive amounts of spatter.

Shielding Gases:
The gasses used in MIG/MAG welding can be either 100% CO2
or Argon + CO2 mixes.
Argon + CO2 mixes: Argon can sustain spray transfer

above 24 volts, and gives a very stable arc with a reduction
in spatter. Argon being a cooler gas produces less
penetration than CO2. Argon in normally mixed with CO2 at
a mixture of between 5-25%
100% CO2: Can not sustain true spray transfer, but gives
very good penetration. The arc is unstable which produces
a lot of spatter and a coarse weld profile.

MODES OF METAL TRANSFER
The current and voltage settings determine the way molten
droplets of weld metal transfer from the tip of the wire to the
weld pool
There are 3 principle modes of droplet transfer, namely
spray transfer
pulsed transfer
dip transfer (short-circuiting)

Dip Transfer: (Voltage < 22) / (Amperage < 200)
Thin materials positional welding
Globular Transfer: Between Dip & Spray Transfer
Limited commercial, Used only in some mechanised MAG
process using CO2 shielding gas
Thicker materials, limited to flat welding positions, high deposition

Pulse Transfer: Both spray and dip transfer in
one mode of operation, frequency range 50-300 pulses/second
Positional welding and root runs
Spray Transfer: (Voltage > 27) / (Amperage > 220)
MIG/MAG - metal transfer modes

Electrode diameter = 1,2
mm
Voltage
WFS = 8,3 m/min

Current = 295 A
Voltage = 28V
Globular
transfer
Spray transfer
Electrode diameter = 1,2 mm
Current = 145 A
Voltage = 18-20V
Dip transfer
Current
Current/voltage conditions
WFS = 3,2 m/min
MIG/MAG-methods of metal transfer

Dip transfer
Transfer occur due to short circuits
between wire and weld pool, high level
of spatter, need inductance control to
limit current rise
Can use pure CO2 or Ar- CO2 mixtures
as shielding gas
Requires low welding current/arc

voltage, a low heat input process.
Resulting in low residual stress and
distortion
Used for thin materials and all position
welds
Metal transfer occur when arc is

extinguished
Current 2
Pinch force P
CSA
The pinch effect
Globular transfer
Transfer occur due to gravity or
short circuits between drops and
weld pool
Requires CO2 shielding gas
Metal transfer occur in large drops
(diameter larger than that of
electrode) hence severe spatter
Requires high welding current/arc
voltage, a high heat input process.
Resulting in high residual stress
and distortion
Non desired mode of transfer!
Transfer occur due to pinch effect

NO contact between wire and weld
pool!
Requires argon-rich shielding gas
Metal transfer occur in small

droplets, a large volume weld pool
Requires high welding current/arc

voltage, a high heat input process.
Resulting in high residual stress and
distortion
Used for thick materials and

flat/horizontal position welds
Spray transfer
Requires moderate welding current/arc voltage reduced heat input

smaller residual stress and distortions compared to spray transfer
Pulse frequency controls the volume of weld pool used for root
runs and out of position welds
Pulsed transfer
Controlled metal transfer one
droplet per pulse NO transfer during
background current!
Requires special power sources
Metal transfer occur in small droplets
(diameter equal to that of electrode)

Pulse current parameters
Current (A)
Transition
current
Average current
(ammeter reading)
Background
current
Time (sec)
Peak
current

Pulsed Transfer
Current
Ip = peak current
(spray transfer)
Ib = background current
(continuous arc but little or no fusion)
Ib
Tp
Tb
Tp = peak time
Tb = background time
Time
Ip
Electrode
extension
6-13 mm
Electrode
extension
19-25 mm
Contact tip
extension
(0-3,2 mm)
Contact tip
recessed
(3-5 mm)
Set-up for dip transfer
Set-up for spray transfer
The effect of inductance

Controls the rate of current rise
Current (A)
Excessive current, high
spatter
No inductance
ance a
Induct
dded
Desired current for

good stability, low
spatter
Time (sec)
Short circuit
current
The effect of inductance

reduced spatter
Hotter arc more
penetration
More fluid weld pool
flatter and smoother weld
Recommended on thicker
materials and stainless
steels
Minimum inductance
Colder arc used only for
arc stability when welding
wide gaps
Convex weld, more spatter
Improved weld pool control
Recommended on thin
materials
Maximum inductance
MIG/MAG process variables

Welding current
Increasing welding current

Increase in depth and width
Increase in deposition rate
Polarity
MIG/MAG process variables
Electrode
orientation
Deep
Moderate Shallow
Excess weld metal Maximum Moderate Minimum

Undercut
Severe Moderate Minimum
Electrode
extension
Increased extension
Penetration
Types of Shielding Gas

MIG (Metal Inert Gas)
Inert Gas is required for all non-ferrous alloys (Al, Cu, Ni)
Argon + Helium used to give a hotter arc - better for thicker

joints and alloys with higher thermal conductivity
Most common inert gas is Argon

Types of Shielding Gas
MAG (Metal Active Gas)
Active gases used are Oxygen and Carbon Dioxide
Typical active gases are

Ar + 20% CO2
Ar + 2% O2
100% CO2
for C-Mn & low alloy steels

for stainless steels
can be used for C - steels
Argon with a small % of active gas is required for all steels

(including stainless steels) to ensure a stable arc & good droplet
wetting into the weld pool
MIG/MAG shielding gases
Carbon steel
Stainless steel
Aluminium
Shielding gas
CO2 , Ar+(5-20)%CO2
Ar+2%O2
Ar
Type of material

Pulsed Transfer
Transfer-mode advantages
Good fusion
Small weld pool allows all-position welding
More complex & expensive power source

Difficult to set parameters - requires power source
manufacturer to provide pulse programmes to suit wire type,
dia. and type of gas
Transfer-mode disadvantages

Types of Filler Wire
Filler wires have similar composition to the base material
Wires can be solid, flux cored or metal cored
The slag formed from flux cored wire enables welding to be done in
all-positions
Most flux cored wires have a folded seam that can allow moisture to
get into the flux
Controlled storage & handling is required for seamed wires
Metal cored wires have the same general characteristics as solid
wires - they can be operated in dip or spray mode
Some flux cored wires do not require a gas shield (Innershield)
Flux cored wires are designed to run in spray mode and therefore
they give good fusion
Flux cored wires cannot be used for root runs on unbacked joints
Checks when GMAW welding

The welding equipment
A visual check should be made on the equipment to
ensure it is in good working order
The electrodes
The diameter, specification and the quality of the wire
are essential for inspection. The level of deoxidisation in

the wire, single, double or triple de-oxidised. The quality
of the wire winding and the copper coating should also
be inspected to minimize wire feed problems.
Wire liner
Check that the liner is the correct type and size for the wire
being used. Steel liners for steel and Teflon liners for
aluminium.
Contact tips
Check the tip is the correct size for the wire being used and
check the amount of wear. Excessive wear will affect wire
speed and electrical current pick-up
Gas and gas flow-rates
Type of gas and the flow rate need to be checked to ensure
they comply with the WPS
Other welding variables
Check WFS, amps, volts and travel speed
Checks when MAG welding
MIG/MAG typical defects

Most welding imperfections in MIG/MAG are caused by lack of
welder skill, or incorrect settings of the equipment
Worn contact tips will cause poor power pick up, or transfer
Bad power connections will cause a loss of voltage in the arc
Silica inclusions (in Fe steels) due to poor inter-run cleaning
Porosity (from loss of gas shield on site etc)

Solidification problems (cracking, centerline pipes, crater
pipes) especially on deep narrow welds
Lack of fusion (primarily with dip transfer)
MIG/MAG Arc Welding

Disadvantages
High productivity
Lack of fusion (dip)
Easily automated
Small range of consumables
All positional (dip & pulse)
Protection on site
Material thickness
Complex equipment
range
Continuous electrode
Not so portable
Advantages
Questions
Metal Active Gas Welding
QU 1. State the possible problems when using the dip transfer
mode in the MAG welding process
QU 2. State the application areas for the spray transfer mode
when using the MAG welding process.
QU 4. State the main variables for the MAG welding process

QU 5. State the advantages and disadvantages of the MAG
welding process when compared to MMA
QU 3. What power source characteristic is required and electrode

polarity/current type for the MAG welding process
Flux Core Arc Welding
Flux cored arc welding
With gas
shielding Outershield
Without gas
shielding Innershield
With metal
powder Metal core
FCAW
methods
Outershield - principle of operation
Innershield - principle of operation
ARC CHARACTERISTICS
Constant Voltage Characteristic
OCV
Large arc gap
Small change in voltage =

large change in
amperage
The self
adjusting arc.
Volts
Amps
Small arc gap
usually operates in DCEP

but some Innershield
wires operates in DCEN
power sources need to
be more powerful due to
the higher currents
doesn't work in dip
transfer mode
require knurled feed rolls
Innershield wires use
a different type of
welding gun
FCAW - differences from MIG/MAG

350 Amps self shielded welding gun
24V insulated
switch lead
Handle
Trigger
Thread protector
Contact tip
Courtesy of Lincoln Electric
Hand shield
Welding
gun cable
Close wound stainless

steel spring wire liner
(inside welding gun
cable)
Conductor
tube
Self shielded electrode

nozzle
75
90
75
Travel Angle
Backhand (drag) technique

Advantages
preferred method for flat or horizontal position
slower progression of the weld
deeper penetration
weld stays hot longer easy to remove dissolved
gasses
Disadvantages
produce a higher weld profile
difficult to follow the weld joint
can lead to burn-through on thin sheet plates
Forehand (push) technique

Advantages
Disadvantages
produce a low weld profile, with coarser ripples
fast weld progression shallower depth of penetration
the amount of spatter can increase
preferred method for vertical up or overhead

position
arc is directed towards the unwelded joint
preheat effect
easy to follow the weld joint and control the
penetration
less sensitive to lack of fusion

requires smaller included angle compared to MMA
high productivity
all positional
smooth bead surface, less danger of undercut
basic types produce excellent toughness properties
good control of the weld pool in positional welding
especially with rutile wires
seamless wires have no torsional strain twist free
ease of varying the alloying constituents
no need for shielding gas
FCAW advantages
FCAW advantages
Deposition rate for carbon steel welding
limited to steels and Ni-base alloys

slag covering must be removed
FCAW wire is more expensive on a weight basis
than solid wires (exception: some high alloy steels)
for gas shielded process, the gaseous shield may be
affected by winds and drafts
more smoke and fumes are generated compared
with MIG/MAG
in case of Innershield wires, it might be necessary to
break the wire for restart (due to the high amount of
insulating slag formed at the tip of the wire)
FCAW disadvantages
Advantages:
Disadvantages:
1) Field or shop use
1) High skill factor
2) High productivity
2) Slag inclusions
3) All positional
3) Cored wire is Expensive
4) Slag supports and shapes

the weld Bead
4) High level of fume

(SSFCAW)
5) No need for shielding gas
5) Limited to steels and

nickel alloys
FCAW advantages/disadvantages
Any Questions

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CSWIP 3.

TWI Training & Examination Services

Copyright TWI Ltd 2008

Gas Metal Arc Welding

Gas Metal Arc Welding

The process is classified as a semi-automatic welding

Copyright TWI Ltd 2008

The weld pool is protected by a separately supplied

Copyright TWI Ltd 2008

MIG/MAG - Principle of operation

Gas Metal Arc Welding

Wire burn-off rate is directly related to current

Copyright TWI Ltd 2008

Wire feed speed is directly related to burn-off rate

Equipment for MIG/MAG

Power cable &

Liner for wire

Copyright TWI Ltd 2008

MIG/MAG wire drive system

Copyright TWI Ltd 2008

MIG/MAG wire drive system

Copyright TWI Ltd 2008

Types of wire drive systems:

2 roll wire drive

4 roll wire drive

MIG/MAG wire drive system

recommended for softer

Copyright TWI Ltd 2008

recommended for steel

Copyright TWI Ltd 2008

MIG/MAG wire drive system

MIG/MAG welding gun types

Copyright TWI Ltd 2008

Goose neck type

MIG/MAG welding gun assembly

Welding gun body

Copyright TWI Ltd 2008

MIG/MAG welding gun assembly

Copyright TWI Ltd 2008

Small change in voltage =

Copyright TWI Ltd 2008

Small arc gap

MAG Welding Variable Parameters

The voltage is the most important setting in the spray transfer

Copyright TWI Ltd 2008

MAG Welding Variable Parameters

The inclusion or the choke in the welding circuit controls the

Copyright TWI Ltd 2008

MAG Welding Variable Parameters

Argon + CO2 mixes: Argon can sustain spray transfer

Copyright TWI Ltd 2008

Gas Metal Arc Welding

Copyright TWI Ltd 2008

dip transfer (short-circuiting)

Gas Metal Arc Welding

Thicker materials, limited to flat welding positions, high deposition

Copyright TWI Ltd 2008

Spray Transfer: (Voltage > 27) / (Amperage > 220)

MIG/MAG - metal transfer modes

WFS = 8,3 m/min

Copyright TWI Ltd 2008

WFS = 3,2 m/min

MIG/MAG-methods of metal transfer