MMAW-Manual Metal Arc Welding

&
GMAW-Gas Metal Arc Welding
D.SELVAKUMARAN
COURSE DIRECTOR (SSE) / AWTI
Classification of Welding Processes
 ARC WELDING
MANUAL METAL ARC WELDING
TIG WELDING
MIG/MAG WELDING
SUBMERGED ARC WELDING
PLASMA ARC WELDING
CARBON ARC WELDING
ELECTRO SLAG WELDING
 RESISTANCE WELDING
SPOT WELDING
SEAM WELDING
BUTT FLASH WELDING
PROJECTION WELDING
BUTT WELDING
STUD WELDING
 GAS WELDING
OXY-ACETYLENE GAS WELDING
OXY-HYDROGEN GAS WELDING
OXY-COAL GAS WELDING
OXY-LPG GAS WELDING
AIR ACETYLENE GAS WELDING
 SPECIAL WELDING PROCESS
THERMIT WELDING
LASER BEAM WELDING
ULTRASONIC WELDING
EXPLOSIVE WELDING
COLD PRESSURE WELDING
SOLDERING / BRAZING / PLASTIC WELDING
FORGE WELDING
FRICTION WELDING
 MMAW Manual Metal Arc Welding
Basic principles of MMAW process
What is Arc?
Heat is generated Q=I2RT
or Q = VI/S
2/3 heat at positive (electrode)
1/3 heat at job
Arc length is related to the arc voltage
Electrodes coated with flux produces
gaseous shield.
Flux ingredients combine with iron
oxide and other impurities and slag is
formed called scavenging action.
 MMAW Manual Metal Arc Welding
80V
OPEN
Power sources : CIRCUIT
VOLTAGE
Constant current 25
SHORT
Evolution of power sources CIRCUIT
transformer
transformer rectifier VOLTAGE
transistor controlled power supply
inverter based digital/analog CURRENT
IGBT

Peak
current
Base
current
 MMAW Manual Metal Arc Welding
Basic Process parameter :
Current-voltage
OCV
Arc length
Electrode angle, job Angle
Travel speed
Polarity
 Basic Process parameter
voltage
Determines heat generated
Fixed no user adjustment
Higher OCV easier arc initiation
current
Essential variable
Determined by electrode thickness
Speed of welding
Too high current results in Undercut, spatter, burn
through
Too low current improper penetration, fusion, over lap
 Basic Process parameter
Arc length

Medium arc arc length equal to electrode

thickness
Long arc leads to improper weld bead,
spatters, undercut, porosity, under cut etc.
Short arc useful in position welding
 Basic Process parameter
Job angle
Incorrect Job angle leads to
Unequal leg length
Lack of sidewall fusion
undercut
 Basic Process parameter
Electrode angle
Incorrect electrode angle leads to
Lack of Penetration
porosity
 Basic Process parameter
Travel speed
Both slow & Fast travel leads to
lack of penetration
Slow travel results in overlap, excessive
weldment
 Basic Process parameter

Polarity
Heat is generated Q=I2RT
or Q = VI/S
Reverse polarity (DCEP) generally used
straight polarity (DCEN) used in TIG only
2/3 heat at positive (electrode)
1/3 heat at job
 MMAW Manual Metal Arc Welding
Types of flux coatings / coverings:
Cellulosic coverings:
organic materials like cellulose, wood flower and wood pulp.
The presence of hydrogen increases arc voltage across the arc and makes it more
penetrating.
The surface profile is poor, while the mechanical properties are good, the hydrogen content
being very high, restricts the use of this type of electrode on high strength steels.
Rutile coverings:
It contains mostly Titanium oxides.
This compound has good slag forming characteristics and produces stable arc.
Rutile electrodes are widely used in fabrication industries.
Basic coverings (Low Hydrogen type):
It contains mainly calcium compounds such as calcium fluorides, and calcium carbonates.
These electrodes are mainly used for welding of high strength steels.
 CLASSIFICATION OF ELECTRODES (AWS 5.1)

E6010
Electrode

60X000
Psi Welding
position Coating and current
70
conditions
80
90
100
110
120
 CLASSIFICATION OF ELECTRODES (AWS 5.5)

E 80 1 8 (IRS Class D)

Electrode
80,000 Psi
All position
1-F,H,V,OH 2-F,H , 4-F,H,VD,OH
0 CELLULOSE SODIUM DCEP

1 CELLULOSE POTASSIUM AC/DCEP/DCEN

2 TITANIA SODIUM AC/DCEN

3 TITANIA POTASSIUM AC/DCEP

4 IRON POWDER TI AC/DCEN/DCEP

5 LOW HYDROGEN Na DCEP

6 LOW HYDROGEN K AC/DCEP

7 Fe POWDER Fe OXIDE AC/DCEP/DCEN

8 Fe POWDER LOW H2 AC/DCEP

 IRS M 28-02
(Cl. 3.1)

CLASSIFICATION OF ELECTRODES AS PER

THEIR APPLICATION
 Metal Transfer

Factors influencing metal transfer:

> Surface tension
> Force of gravity
> Magnetic forces
> Gas expansion force
> arc blow
 Metal Transfer
Factors influencing metal transfer:
> Gas expansion force
> arc blow
Surface tension forces:
> Holds the liquid metal droplet to the tip.
Force to be overcome
Force of gravity:
> Position of welding
Flat --- Helps in metal transfer
Overhead--Negative influence oppose metal transfer
Magnetic forces:
Pinch forces.
Gas expansion forces:
Transfers metal
Controls the scattering of molten metal
Arc blow
Deflection of Arc due electric/electromagnetic /magnet disturbance
 Welding defects
lack of fusion
Porosity
Slag inclusions
Undercut
Excessive Asymmetry of Fillet weld
Excessive weld metal
Excessive penetration
Cracks
Lack of penetration
Linear misalignment
Crate crack and crater pipe
spatter
Overlap
 GMAW
[Gas Metal Arc Welding]

MIG MAG
Metal Inert Gas Welding Metal Active Gas Welding

Argon, Helium. CO2 or Argon+CO2 mixed gas.

Non-Ferrous metals Ferrous metals - All types of
Aluminum, Copper steels
GMAW
 Gas Metal Arc Welding - GMAW
high deposition rate
Wire is continuously fed from a spool.
semiautomatic welding process
High current density
Self adjusting arc
Different modes of metal transfer
Gas mixtures can be used
Higher welding speed
All position capability
Less operator skill required
Long welds can be made without starts and stops
Low heat input
Easy to automate
Minimal post weld cleaning is required
 Equipment for GMAW process

DC Current is required for GMAW process

a. Transformer /Rectifier/inverter/IGBT
power sources are mainly used.
b. They are designed to have a constant
Voltage characteristics (Flat Type).
c. The welding is carried out on DCEP.
d. A wire feed unit with variable wire feed
speed settings is used.
e. Here welding current is directly related
to the wire feed rates. Therefore, for
attaining high deposition rates the wire is
fed at higher feed rates.
Equipment for GMAW process
- Euro adapter
- Cable
- Liner
- Gas diffuser
- Contact tip
- Nozzle
CONSTANT VOLTAGE
CHARACTERISTICS

VOLTAGE

20 V
ARC
VOLTAGE

CURRENT
 Basic welding parameters in GMAW
The basic parameters which require to be set in
GMAW process are
Current ( amps )
Voltage ( volts )
Shielding gas flow rate. ( litres / min )
Stick out
Torch angle
Welding speed
 Basic welding parameters in GMAW
Current ( amps )
Linked with wire speed
Matching Amount Wire pushed & burning rate
Voltage ( volts )
Less voltage gives peaked bead
More voltage spreads the bead; more flat
bead
 Basic welding parameters in GMAW

Shielding Gas
shields the arc and molten weld pool
stabilizes the arc
allows smooth transfer of metal
 Basic welding parameters in GMAW
The primary shielding gasses used are:
Argon
co2
Argon - 1 to 5% Oxygen
Argon - 3 to 25% CO2
Argon/Helium
 Basic welding parameters in GMAW
Shielding gas flow rate
Required to prevent oxidation
Low & high flow rate results in porosity
Should be matched with deposition rate
 Basic welding parameters in GMAW
Stick out
Longer stick out reduces penetration
Longer stick out increases dposition
For Higher parameter (V,I) more stick out
 Mode of metal transfer

Short circuiting transfer

Globular transfer
Spray transfer
Short circuiting / Dip transfer
 Short circuiting transfer

Low current - low voltage used to produce

short circuiting arc, freq. 70 times /second.
Used for sheet metal and positional welding
16-22 volts.
Globular transfer
 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.
Spray transfer
 Spray transfer

Higher currents and voltage used, droplet size same

as or lower than the wire diameter.
weld pool of low viscosity
About 100 to 300 droplets transferred per second
Higher deposition rate penetration and fluidity of the
molten pool , increases the productivity
24-38 volts.
Pulse Spray transfer
 Pulse Spray 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.
In synergic pulsed systems wire feed rate
synchronised with pulsed current to control
individual droplet detachment.
Mode of metal transfer
Electrode wire size Current (amps)
(mm)

Short Arc Spray Arc

0.8 50 150

1.2 100 240

1.6 175 300

2.4 --- 400

 BASIC WELDING PARAMETERS IN GMAW PROCESS

If the wire feed speed is too high the wire will not be melted fast enough
and will pass through the arc hitting the plate, which is known as stubbing.
The resultant weld is peaky with little fusion and a lot of spatter.
 Selection of Arc Voltage

Factors to be considered:
Wire speed/Current
Mode of metal transfer
Shielding gas
Stand - off distance

Empirical relationships:
V = 14 + (0.04 x I ) For short arc
V = 16 + (0.04 x I ) For spray arc
 Self-regulation of the arc
Constant voltage or potential power sources
The current adjusts itself to burn off rate
for a small change in arc length there is a large
change in welding current which makes it
quite sensitive and helps in maintaining a
steady arc length which gives consistent quality
welds.
This is called self-regulation of the arc length and
is a requirement for success of GMAW welding.
Classification of Carbon steel consumable
electrode wires meant for CO2 welding
applications [ AWS A5.18 ]

E70S-6
E - electrode wire
70 - UTS
S - Solid wire
6 - Chemical composition of the wire
Chemical Composition filler wire in weight %
(Wire: ER 70S6 AWS A5.18)

C: 0.07-0.15
Mn: 1.4-1.8
Si: 0.8-1.15
S: 0.035
P: 0.025
IRS M46
 MIG Welding Problems

Heavily oxidized weld deposit

Irregular wire feed
Burnback
Porosity
Thank you