Gas Metal Arc Welding

Metal Inert Gas Welding (Gas Metal Arc Welding) is a arc welding process, in which the weld is shielded by
an external gas (Argon, helium, CO2, argon + Oxygen or other gas mixtures).
 Advantage of GMAW
•There is no slag produce so it's post weld cleaning is minimal. 

•Being that the electrode is a continuous wire it allows for long welds without the need to stop.

•GMAW can have high travel speeds and deposition rates if it is compared to Shielded Metal Arc Welding
(Stick/SMAW), which can save money on down time.

•This process can be used in every position which is an advantage over the SAW welding process.

•It can be Automated for high production with repeatable parts.

•It is an process that is sometimes considered to be easier to learn than other processes.

•The Process is Capable of welding Dissimilar metals.

MIG Welding Transfer Methods
• In MIG welding, there are four different basic modes to transfer weld metal (filler material) across
the arc to the base material. These transfer modes are Short Circuit, Globular, Spray Arc and
Pulsed MIG. 
• The different transfer methods are how the weld metal from the consumable electrode is
transferred to the base material over the arc. There are no settings on a MIG welder to choose a
transfer method - each method is achieved through voltage / amperage (wire feed speed) setting
adjustments and the type of shielding gas mixture used.
Short Circuit transfer
• Short circuit, commonly called “short arc” and formally called GMAW-S, is a mode of metal
transfer with low heat input where the transfer of metal from the electrode to weld puddle
occurs by a series of electrical shorts. As the welding wire is fed it makes physical contact with the
base material and creates a short. As the short occurs the voltage immediately drops to zero.
However, mig welding machines are constant voltage power sources and their main job is to keep
the voltage constant.  In order to do so in the presence of short, which wants to drive the voltage
to zero, the power source will increase the amperage to break the short.
• The short is essentially blasted away by the spike in amperage causing an explosion of sorts.  This
explosion generates spatter
Advantages of Short Circuit Transfer
• Good for thinner materials (1/8” and under) – low heat input prevents blowing through the base
material and as long as the travel speed is adequate can also prevent distortion.
• All-position welding – due to the low heat input the puddle solidifies quickly which allows for
welding in all positions.
• Low cost – The low amperage requirement of short circuit transfer means that basic, low-end
power sources can be used.

Limitation of Short Circuit Transfer

• Limited to sheet metal – as mentioned above, the low heat input produces lack of fusion on thicker
sections.
• Spatter – the shorting of the arc and subsequent blasting of the arc by the spike in amperage
generates spatter which increases clean up time and reduces the electrode efficiency.
• Not allowed for use in prequalified welding procedures (due to susceptibility to lack of fusion).
Globular Metal Transfer
• Globular transfer occurs in GMAW and MCAW processes after we exceed a certain current for a
specific wire diameter.  Instead of having the metal transfer via a series of shorts as in short circuit
transfer, in the globular transfer method gravity pulls down on large metal droplets (globs) that
form at the end of the wire due to the high currents associated with this mode.
• The difference between globular and short circuit transfer is in the current and voltage levels. 
Globular uses higher currents and higher voltages.  For GMAW wires the current at which short
circuit stops and globular transfer starts are listed below:
Advantages of Globular Transfer

•Low cost – basic constant voltage equipment and relatively inexpensive carbon dioxide shielding
gas may be used.
•High heat input permits the welding of thick sections
•Lower emitted heat compared to spray (for operator comfort)

Limitations of Globular Transfer

•Excessive spatter adds rework (time spent removing spatter)

•Excessive spatter decreases the efficiency of the wire (wasted filler metal)
•Limited to the flat and horizontal positions due to large fluid weld puddle
•Erratic/Inconsistent arc
Spray Transfer
• Spray is a mode of metal transfer in which a fine spray of metal droplets are projected axially
from the tip of the electrode to the work.  These droplets are smaller in diameter than the
electrode.  This mode of transfer is characterized by high wire feed speeds (high amperage), high
voltage and consequently high heat input.  It produces a very fluid weld puddle so it can only be
used in the flat and horizontal positions.
The welds produced with spray transfer are characterized by deep penetration and excellent
bead appearance, provided proper welding technique is used.
In order to achieve spray transfer the welding procedure should be such that it provides
amperage above the transition current and the corresponding voltage to achieve a stable arc.
The amperage level at which we attain spray transfer is dependent primarily on two variables:
• Shielding gas composition
• Electrode diameter
In order to achieve spray transfer the shielding gas should contain at least 80% argon
(inactive/inert gas) with the balance being most commonly carbon dioxide and in some cases
oxygen (at levels of 5% or lower).  Gases of these compositions provide a stable medium for
the metal droplets to transfer smoothly through the arc.
Advantages of Spray Transfer
• High heat input which can provide deep penetrating welds
• Higher wire feed speeds (amperage) produce high deposition rates which increase
productivity
• Very clean, spatter free welds possible
• Good choice for thicker sections (1/4-inch and thicker)
• Allows for use of prequalified welding procedures
Limitations of Spray Transfer
• Use is limited to the flat and horizontal positions due to puddle fluidity
• Potential for burn-through on thinner materials
• Potential for undercut due to high voltage levels
• More expensive gas than for short circuit or globular
• Higher levels of radiated heat – uncomfortable for the welder
Pulse Transfer
• Pulsed spray refers to a GMAW mode of transfer in which metal droplets are transferred through
the arc with changes in amperage produced by the power source.  The power source provides a
pulsing peak current that raises the amperage above the transition current and allows for axial
spray transfer.  This peak current is only applied for a short time (measured in milliseconds) and
then a background current takes over. The background current is high enough to keep the arc lit,
but low enough prevent metal transfer, meaning metal transfer only occurs while the peak
current is applied.

In order to achieve pulsed spray we need to meet all the requirements of spray transfer which are:
• Shielding gas argon content of at least 80% (balance carbon dioxide or oxygen)
• Welding current above transition point for the wire diameter being used (only peak current has to
be above)
Advantages of Pulse Welding
• Reduction in spatter
• Higher deposition rates for out-of-position welding
• More resistant to lack of fusion than  short circuit and globular transfer
• Reduction in overall heat input
• Good on thin materials 
• Reduces fume levels
Limitations of Pulse Welding
• Cost of equipment
• Cost of gas
• Higher radiated heat