Introduction to GMAW

Yeong-Do Park, Ph.D

Associate Professor, Director of Center for
Education of Welding Engineering
Department of Advanced Materials Engineering

Content

Introduction
GMAW process and Equipments
Shielded Metal Arc Welding (SMAW)
Defects in GMAW
Safety

 Introduction

Classification of Welding Processes

Arc Welding Overview

All arc welding uses an electric arc to produce a weld by melting the
base material and filler metal, if applicable
Three main differences between arc welding processes:
How the welding arc is initiated and controlled
Consumable electrodes
Melt and transfer to the weld for filling joint
The electrode is the filler metal
Non-consumable electrodes
Provide electrode for arc and generally do not melt
Tungsten or Carbon
Filler material, when used, is provided separately
How the molten metal weld pool is shielded
Whether filler metal is used and how it is supplied to the molten weld pool

Basic Arc Welding Circuit

Primary Operating Parameters

Arc voltage / arc length

Arc current
Electrode feed rate (consumable)
Welding travel speed
Electrical polarity

Need for Atmospheric Shielding

Molten metal reacts with the atmosphere to form oxides and

nitrides
Porosity will result if the weld pool is exposed to the atmosphere
Metallurgical changes can occur
Weld mechanical properties are generally reduced
The weld area should be free of dirt, grease, paint, scale, and
other foreign objects to ensure weld quality
Fluxes and shielding gasses are not designed to scavenge these
components from the solidifying weld metal

Sources of Shielding

Flux Shielding

Decomposes and provides a gas to shield the arc and prevent

atmospheric contamination of the molten filler metal and weld pool
Provides scavengers, deoxidizers, and fluxing agents to cleanse the
weld and prevent excessive grain growth in the weld metal
Establishes the electrical characteristics of the electrode
Provides a slag blanket to protect the hot weld bead from the air
and can enhance the mechanical properties, weld bead shape and
surface cleanliness
Provides a means of adding alloying elements to change the
mechanical properties of the weld metal

Gas Shielding

Purges the weld area to shield the molten metal from the atmosphere
Argon is the most common inert gas
CO2 is sometimes used
Less expensive
Similar to gases produced from fluxes

CO2 and O2 are commonly mixed with argon

Promotes oxidation to stabilize the arc and metal transfer
Improves weld bead wetting

H2 can be added to increase arc heat in some cases

Helium may also be used to increase arc heat
Requires addition of deoxidizers to filler materials

Gas Metal Arc Welding Source

GMAW Equipment

GMAW Pros & Cons

Advantages
Welds all commercial metals
All positions
High deposition rates compared to GTAW and SMAW
Continuously fed filler wire
Long welds without stops and starts
Minimal post-weld and inter-pass cleaning

Disadvantages
Welding equipment is more complex than that for SMAW
More difficult to use in hard to reach places
Welding torch size
Welding torch must be kept in close proximity to the workpieces in order to
achieve adequate shielding
Arc must be protected against air drafts

 GMAW process and Equipments

The welding Arc

Effect of polarity

DCEP (Direct Current Electrode Positive): Electrode (+), base metal(-).

Also known as reverse polarity.
DCEN (Direct Current Electrode Negative): Electrode (-), base metal(+).
Also known as straight polarity.

Welding Power Source Characteristics

Welding power source delivers a
controllable welding current at a demanded
voltage.
The illustrated graph shows Voltage at
different arc length when plotted against
welding current.
The highest voltage is the open circuit
voltage of the power source.
The voltage gradually decreases as the gas
between the arc gap becomes ionized and
electrically conductive.
The welding current increases as the
voltage falls until a point is reached at
which time the voltage/current relationship
becomes linear and begins to follow Ohms
Law.
as the arc length changes both the voltage
and welding current also change a longer
arc giving higher voltage but with a
corresponding drop in welding current and
vice versa.

Welding Power Source Characteristics

Constant Current Characteristics

Relatively small change in amperage and arc

power for corresponding relatively large
change in arc voltage or arc length.
Used primarily with coated electrodes.
In welding with coated electrodes, the output
current or amperage is set by the operator while
the voltage is designed into the unit. The
operator can vary the arc voltage somewhat by
increasing or decreasing the arc length. A
slight increase in arc length will cause an
increase in arc voltage and a slight decrease in
amperage. A slight decrease in arc length will
cause a decrease in arc voltage and a slight
increase in amperage

Welding Power Source Characteristics

Constant Voltage Characteristics

when using a constant voltage power source

and a wire feeder that delivers the wire at a
constant speed, arc length caused by operator
error, plate irregularities, and puddle movement
are automatically compensated for by the
characteristics of this process.
Used primarily with solid and flux cored
electrodes.
condition #2 produces the desired arc length,
voltage and amperage. If the arc length is
increased as in #1, the voltage increases
slightly; the amperage decreases and therefore,
the melt-off rate of the wire decreases. If the
arc length is decreased as in #3, the voltage
drops off slightly, the amperage is increased,
and the melt-off rate of the wire increases.
Since the wire is now melting off faster than it
is being fed, it melts back to the proper arc
length where the melt-off rate equals the
feeding rate.

Power Source in GMAW

Almost all GMAW is done with reverse polarity also
known as DCEP
Positive (+) lead is connected to the torch
Negative (-) lead is connected to the work piece
Provides a relatively consistent voltage to the arc
Arc Voltage is the voltage between the end of the wire
and the work piece.

Shielding Gases
Purpose of shielding gas is the protect the weld area
from the contaminants in the atmosphere
Gas can be Inert, Reactive, or Mixtures of both
Gas flow rate is between 25-35 CFH
Argon, Helium, and Carbon Dioxide are the main
three gases used in GMAW

Properties of Gases
Affect the performance of the welding process include:
1) Thermal properties at elevated temperatures.
2) Chemical reaction of the gas with the various
elements in the base plate and welding wire.
3) Effect of each gas on the mode of metal transfer.

Types of shielding gases

Inert Gas
1. Argon
2. Helium
3. Ar + He
Active Gas
1. Carbon Dioxide
2. Inert gas + any type of active gas

Types of shielding gases

Argon is an inert gas which is used both as pure and in
combination with other gases to achieve desired arc
characteristics for the welding of both ferrous and
non-ferrous metals.
Carbon Dioxide Carbon dioxide is not an inert gas.
because the heat of the arc breaks down the CO2 into
carbon monoxide and free oxygen. This oxygen will
combine with elements transferring across the arc to
form oxides which are released from the weld puddle in
the form of slag and scale.

Types of shielding gases

Helium is an inert gas which is used on weld applications
requiring higher heat input for improved bead wetting,
deeper penetration and higher travel speed. In GMAW it
does not produce as stable an arc as argon. Compared to
argon, helium has a higher thermal conductivity and
voltage gradient.

Effect of shielding gases

Shielding gas can
affect

Ar

Ar-He

He CO2

Weld bead shape

Arc heat, stability, and
starting
Surface tension
Drop size
Puddle flow
Spatter

Application of shielding gases

Types of Metal Transfer

The basic GMAW process includes three
distinctive process techniques:
Short Circuit (Short Arc)
Globular Transfer
Spray Arc Transfer

Modes of Metal Transfer in GMAW

Short Circuit (Short Arc)

Operates at low voltages and welding current
Small fast-freezing weld puddle obtained
Useful in joining thin materials in any position, as well
as thick materials in vertical and overhead positions.
Metal transfer occurs when an electrical short circuit is
established.
this cycle can repeat itself between 20 and as much as
250 times per second.

Short Circuit (Short Arc)

Short Circuit
A - Electrode is short circuited to base metal. No
arc, and current is flowing through electrode wire
and base metal.
B - Resistance increases in electrode wire causing
it to heat, melt and neck down.
C - Electrode wire separates from weld puddle,
creating an arc. Small portion of electrode wire is
deposited which forms a weld puddle.
D - Arc length and load voltage are at maximum.
Heat of arc is flattening the puddle and increasing
the diameter tip of electrode.
E - Wire feed speed overcomes heat of arc and
wire approaches base metal again.
F - Arc is off and the short circuit cycle starts
again.

Short Circuit (Short Arc)

Schematic of short circuit metal transfer mode.

Advantages
All-position capability, including flat, horizontal,
vertical-up, vertical-down and overhead.
Handles poor fit-up extremely well, and is capable of
root pass work on pipe applications.
Lower heat input reduces weldment distortion.
Higher operator appeal and ease of use.
Higher electrode efficiencies, 93% or more.

Limitations
Restricted to sheet metal thickness range and open
roots of groove joints on heavier sections of base
material.
Poor welding procedure control can result in
incomplete fusion. Cold lap and cold shut are
additional terms that serve to describe incomplete
fusion defects.
Poor procedure control can result in excessive spatter,
and will increase weldment cleanup cost.
To prevent the loss of shielding gas to the wind,
welding outdoors may require the use of a
windscreen(s).

Globular Transfer
Globular mode of metal transfer
is obtained at a higher voltage
and current than short circuit
transfer.
A higher wire feed rate can be
used hence can obtain a higher
deposition rate.
A minimum of 25% of Carbon
dioxide is required to obtain
globular transfer.

Advantages
Uses inexpensive CO2 shielding gas, but is
frequently used with argon/CO2 blends.
Is capable of making welds at very high travel speeds.
Inexpensive solid or metal-cored electrodes.
Welding equipment is inexpensive.

Limitations
Higher spatter levels result in costly cleanup.
Prone to cold lap or cold shut incomplete fusion defects,
which results in costly repairs.
Weld bead shape is convex, and welds exhibit poor
wetting at the toes.
High spatter level reduces electrode efficiency to a range
of 87 93%.
Less desirable weld appearance than spray arc transfer.
Welding is limited to flat positions and horizontally fillet
welds.
Welding is limited to metal 1/8 inch (3 mm) or thicker.

Spray Arc Transfer

Occurs when the current and voltage settings are
increased higher than that used for Globular Transfer.
Used on thick sections of base material, best suited for
flat position due to large weld puddle.
Spatter is minimal to none.
Uses 5% to 10% CO mix with argon or oxygen.
>Forms very small droplets of metal
>Very good stability
>Very little spatter

Spray Arc Transfer

Spray arc transfer sprays a stream
of tiny molten droplets across the
arc, from the electrode wire to the
base metal.
Spray arc transfer uses relatively
high voltage, wire feed speed and
amperage values, compared to short
circuit transfer.

Advantages
High deposition rates.
High electrode efficiency of 98% or more.
Employs a wide range of filler metal types in an
equally wide range of electrode diameters.
Excellent weld bead appearance.
High operator appeal and ease of use.
Requires little post weld cleanup.
Absence of weld spatter.
Excellent weld fusion.
Lends itself to semiautomatic, robotic, and hard
automation applications.

Limitations
Restricted to the flat and horizontal welding
positions.
Welding fume generation is higher.
The higher-radiated heat and the generation of a very
bright arc require extra welder and bystander
protection.
The use of axial spray transfer outdoors requires the
use of a windscreen(s).
The shielding used to support axial spray transfer
costs more than 100% CO2.

GMAW Filler Metal Designations

ER - 70S - 6
Electrode
Rod (can be used
with GMAW)

Composition
6 = high silicon
Solid Electrode
Minimum ultimate tensile
strength of the weld metal

Wire Chemistries

GMAW Operation techniques

Setting the wire feed speed

GMAW Operation techniques

Effect of Welding Current

Wire feed speed depends on the welding current

As welding current is increased, penetration also is increased due to increasing of
heat input and arc force
In general, if welding current is increased, also arc voltage is increased
accordingly.

Effect of Welding Voltage

Welding condition
BM : carbon steel t9
-Solid wire 1.2
-- Current : 280A
-- CO2 gas 20L/min
-- CTWD 20mm
-- Welding speed : 40cm/min

With increasing voltage the bead

width increases.
Initially with increasing voltage
penetration depth increases. However,
at higher voltage the penetration again
decreases.

Contact Tip To Work Distance

In constant current, the CTWD (contact tip to work distance) determines the arc length.
As the CTWD increases the arc length increases, and as the CTWD decreases the arc length
decreases.
This presented a problem for semiautomatic welding because it is difficult to maintain the
same CTWD.

Contact Tip To Work Distance

Constant voltage power source designs provide a specific arc voltage for a given pre-

selected wire feed speed The volt-amp curve, or slope, is comparatively flat.
As the CTWD increases with these types of power sources, there is a decrease in the
welding current. As the CTWD decreases there is an increase in the welding current.
The arc in this case becomes a series circuit, and the CTWD provides resistance to
current. In either scenario, the voltage remains the same and the arc length remains the
same.

Contact Tip To Work Distance

Electrode Stick-out
Electrode stick-out Setting

Gun angles and techniques

Gun angles and techniques

Gun angles and techniques

Gun angles and techniques

 Defects in GMAW

Classification of Weld Defects

Classification of Weld Defects

Classification of Weld Defects

 Safety

Safety
Electrocution hazard
Skin burns from flying metal
Skin burns from direct light from arc
Skin burns from indirect light from arc
Cotton clothing and leather gloves
Helmet to protect eyes from light
Safety glasses when chipping slag
Ventilation to remove dangerous fumes
Do not weld near water
Do not weld near combustible materials
Keep welding cables and jobs free grease
Protect bystanders from arc rays

Thank You!
Dong-Eui University
Center for Education of Welding Engineer