GAS METAL ARC WELDING (GMAW)

What is GMAW
An arc welding process that uses an arc between a continuous filler metal electrode and the weld pool to produce a fusion (melting) together of the base metal The process is used with a shielding gas supplied from an external source without pressure.

Also Known AS
Wire Feed MIG = Metal Inert Gas
Inert Gas= Inactive gas that does not combine chemically with base or filler metal

MAG= Metal Active Gas

Active Gas= Gas will combine chemically with base or filler metal

Advantages
Variety of Metals All Position Welding Quality Welds Little to No Slag Low Spatter

Disadvantages
Cost Portability Outdoor Welding Clean Base Material

GMAW Safety
Cover all skin to prevent Radiation burns Cover hair to prevent sparks setting hair on fire Wear ear plugs to protect from noise and burning ear drums with sparks Use a 14 shade welding helmet to protect eyes Wear safety glasses at all times Make sure pants pockets are empty

GMAW Equipment
Power Supply
Direct Current Electrode Positive (DCEP)
(Electrons flow from to +)

Wire Feeder
Electrical mechanical device that feed required amount of filler material at a constant rate of speed

GMAW Equipment (Cont)

Welding filler electrode
Small diameter consumable electrode that is supplied to the welding gun by the roller drive system

Shielding Gas
Gas used to protect the molten metal from atmospheric contamination
75%Argon (inert gas) & 25% Carbon Dioxide most common gas used for GMAW

Principles of the GMAW Process

GMAW Set UP
Plug ground wire into (Neg) Terminal Plug Wire Feeder into (Pos) Terminal Select CV-Wire mode Hot start is not used Set Arc Control to -5
-10= soft arc (for use with inert gases) +10= crisp arc (for use with CO2)
(See Next Slide)

Min. Arc Control

Soft Arc Thicker Materials Deeper Penetration More Fluid Weld Pool Flatter / Smoother Weld Reduce Spatter Stainless Steels

Max Arc Control

Crisp Arc Thin Materials Arc Stability On Open Gaps Convex Weld Bead Increased Spatter Colder Arc Improved Weld Pool Control

GMAW Set Up (Cont)

Set Volts
Set Wire Speed
See Chart for proper setting See Chart for proper setting Increase wire speed = Increase amps Decrease wire speed = Decrease amps See Chart for proper setting Pull trigger to get gas flowing then adjust regulator

Set gas flow

Running a Bead
Hold tip 1/16 to 1/8 from work piece Angle of tip should be 10-15 Can push or pull bead
Pull (preferred)
More stable arc Less Spatter Deeper penetration

Push
More spatter Less penetration Good cleaning action

Bead Formation

Wire Burnback
Possible Causes
* Drive Rolls in Poor Condition
* Excessive Welding Voltage * Insufficient Electrical Stickout * Contact Tip in Poor Condition * Spatter on Contact Tip

Corrective Actions
*Tighten, Clean, or Replace Drive Rolls * Reduce Voltage
* Increase Contact Tip to Work Piece Distance * Clean or Replace Contact tip * Remove Spatter

Burnthrough
Possible Causes Actions
* Excessive Amperage
* Improper Travel Angle *Travel Speed Too Low * Insufficient Electrical Stickout

Corrective
*Reduce Amperage
* Use a Push Angle * Increase Travel Speed * Increase Contact Tip to Work Distance

Incomplete Penetration
Possible Causes
* Insufficient Amperage * Improper Travel Angle

Corrective Actions
*Increase Amperage * Use Less of a Drag angle

* Excessive Electrical Stickout

* Weld Joint Too Narrow

* Decrease Contact Tip to Work Piece Distance * Increase the Opening of the Weld Joint

GMAW Process Parameters Steel Material .035 Thickness Gas 75%AR25%CO2 18-19 1/8 18-19 3/16 21-22 1/4 21-22 5/16 23-24 3/8 wire Short-Arc Mode Amps Wire Volts Speed 140-150 160-170 180-190 200-210 220-250 280-300 320-340 360-380 400-420 420-520 23-24 24-25 24-25 25-26 26-27