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    Gas Metal Arc Welding

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    Balakumar
    Gas metal arc welding (GMAW), also known as metal inert gas (MIG) welding, is a semi-automatic welding process that uses a continuous wire electrode and an arc between the tip of the wire and the base material. The arc and molten pool are protected from atmospheric contamination by an inert shielding gas fed through the welding gun. GMAW can be used to weld carbon steel, stainless steel, and non-ferrous metals using various shielding gases and wire types. Key variables that affect the process include current, voltage, travel speed, stick out distance, electrode angle, and shielding gas flow rate.

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    Gas Metal Arc Welding

    Uploaded by

    Balakumar
    259 views52 pages
    Gas metal arc welding (GMAW), also known as metal inert gas (MIG) welding, is a semi-automatic welding process that uses a continuous wire electrode and an arc between the tip of the wire and the base material. The arc and molten pool are protected from atmospheric contamination by an inert shielding gas fed through the welding gun. GMAW can be used to weld carbon steel, stainless steel, and non-ferrous metals using various shielding gases and wire types. Key variables that affect the process include current, voltage, travel speed, stick out distance, electrode angle, and shielding gas flow rate.

    Original Description:

    Welding process

    Original Title

    GMAW

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    Gas metal arc welding (GMAW), also known as metal inert gas (MIG) welding, is a semi-automatic welding process that uses a continuous wire electrode and an arc between the tip of the wire and the base material. The arc and molten pool are protected from atmospheric contamination by an inert shielding gas fed through the welding gun. GMAW can be used to weld carbon steel, stainless steel, and non-ferrous metals using various shielding gases and wire types. Key variables that affect the process include current, voltage, travel speed, stick out distance, electrode angle, and shielding gas flow rate.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    259 views52 pages

    Gas Metal Arc Welding

    Uploaded by

    Balakumar
    Gas metal arc welding (GMAW), also known as metal inert gas (MIG) welding, is a semi-automatic welding process that uses a continuous wire electrode and an arc between the tip of the wire and the base material. The arc and molten pool are protected from atmospheric contamination by an inert shielding gas fed through the welding gun. GMAW can be used to weld carbon steel, stainless steel, and non-ferrous metals using various shielding gases and wire types. Key variables that affect the process include current, voltage, travel speed, stick out distance, electrode angle, and shielding gas flow rate.

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    The key takeaways are that Gas Metal Arc Welding (GMAW) is a semi-automatic welding process where the filler metal in the form of a continuously fed consumable electrode is melted by an arc and the weld area is shielded by an inert or active gas. The different types of wire feeding methods are push, pull and self-contained types. The functions of shielding gas are to prevent contamination, increase fluidity of molten metal, minimize spatter generation and help achieve an even bead finish. Post weld heat treatment involves heat treating the welded assembly in a furnace to relieve internal stresses, soften the heat affected zone and reduce cracking tendency.

    The different types of wire feeding methods in GMAW are push type where the wire is fed into the torch by pushing through a flexible conduit from a remote spool, pull type where feed rollers mounted on the torch handle pulls the wire from a remote spool, and self-contained type where the wire feeder and spool are on the torch itself.

    The functions of shielding gas in GMAW are to prevent air contamination of the weld pool, prevent contamination during metal transfer, increase the fluidity of molten metal, minimize spatter generation, and help achieve an even and uniform bead finish.

    Gas Metal Arc Welding

    What Is GMAW ?
    • A Fusion Welding Process – Semi Automatic
    • Arc Between Consumable Electrode &Work
    • Arc Generated by Electric Energy From a
    Rectifier / Thyrester / Inverter
    • Filler Metal As Electrode Continuously fed From
    Layer Wound Spool.
    • Filler Wire Driven to Arc By Wire Feeder through
    Welding Torch
    • Arc & Molten Pool Shielded by Inert Gas through
    Torch / Nozzle
    Gas Metal Arc Welding
    • MIG – Shielding Gas Ar / Ar + O2 / Ar + Co2

    • MAG – Shielding Gas Co2

    • FCAW – Shielding Gas Co2 With Flux cored


    Wire
    Note:- Addition of 1 – 5% of O2 or 5 – 10% of Co2 in Ar.
    increases wetting action of molten metal
    Power Source For MIG / MAG

    • Inverter- DC
    • Thyrester – DC
    • Motor Generator – DC
    • Rectifier – DC
    Characteristic Of GMAW Power
    Source
    Constant V / Linier Characteristic
    V

    Appx. Horizontal Curve

    V1
    V2

    A
    A1 A2
    Current & Polarity

    DC- Electrode +Ve


    Stable Arc
    Smooth Metal Transfer
    Relatively Low Spatter
    Good Weld Bead Characteristics
    DC- Electrode – Ve, Seldom Used
    AC- Commercially Not In use
    Accessories Of GMAW

    • Power Source
    • Wire Feed Unit
    • Shielding Gas Cylinder, Pressure gauges/
    Regulator, Flow meter ( Heater For Co2 )
    • Welding Torch
    • Water Cooling System (For Water cooled Torch)
    • Earthing Cable With Clam
    Tools For GMAW
    • Head Screen With DIN 13 / 14 Dark Glass
    • Hand Wire Brush / Grinder With Wire Wheel
    • Cutting Pliers
    • Hand Gloves
    • Chipping Hammer / Chisel & hammer
    • Spanner Set
    • Cylinder Key
    • Anti-spatter Spray
    • Earthing Cable With Clamp
    GMAW Torch
    . On / Off Switch

    Shielding Gas
    Torch Handle
    Spring Conduit

    Gas Cup Nozzle Tip


    Filler Wire - Electrode
    Arc
    Job
    Equipment & Accessories
    Pressure Regulator
    Flow Meter

    Shielding Gas
    Heater
    Solenoid (Only For
    Switch Co2)
    Valve
    Shielding Gas
    Cylinder
    Welding Torch Wire Feeder
    Copper Cup Wire Inside Spring Lining
    Electrode / Contact Tip Wire
    Wire Spool
    Argon / Co2
    Arc Shielding
    –
    Work
    Power Source
    With Inductance
    Torch With Cable Max. 3Mtr
    + –
    Types Of Wire Feeding In GMAW
    • Push Type
    – Wire fed in to The torch by Pushing through Flexible
    Conduit From A Remote Spool
    • Pull Type
    – Feed Rollers Mounted on The Torch Handle Pulls the
    Wire From A Remote spool
    • Self Contained
    – Wire Feeder & The Spool On the Torch
    Function Of Shielding Gas In GMAW

    • Prevents Air contamination of weld Pool


    • Prevents Contamination During Metal
    Transfer
    • Increases fluidity of molten metal
    • Minimizes the spatter generation
    • Helps in even & uniform bead finish
    Shielding Gases For GMAW
    • MIG: Argon Or Helium
    For SS, CS, LAS & Non-ferrous Mt & Al
    • MIG: Ar + 1 to 2 % O2, Wire With Add. Mn & Si
    For SS, CS, LAS & Non-ferrous Mt & Al
    • MIG: Ar + 5 to 20 % Co2 Wire With Add. Mn & Si
    For SS, CS, LAS & Non-ferrous Mt & Al
    • MAG: Co2 With Solid Wire
    For CS & LAS
    • FCAW: Co2 With Flux Cored Wire
    For CS, LAS & SS Overlay
    ASME Classification For CS GMAW
    Wire
    • SFA 5.18 : - CS Solid Wire
    ER 70 S – 2, ER 70 S – 3
    ER 70 S – 6, ER 70 S – 7

    • SFA 5.20 :- CS Flux Cored Wire


    E 71 T-1, E 71 T-2 ( Co2 Gas )
    E 71 T-1M, E 71 T-2M ( Ar + Co2 Mix)
    GMAW CS Wire
    • Generally Copper Coated
    – Prevents Oxidation / rusting in Storage
    – Promotes Electric Conductivity in Arcing
    • Available In Solid & Flux Cored
    – Size in mm 0.8, 1, 1.2, 1.6, 2, 2.4, 3
    • Manganese & Silicon ( Mn 1 – 2 %, Si Max 1%)
    – Act As Deoxidizing Agents
    – Eliminate Porosity
    – Increase Wetting Of Molten Pool
    Metal Transfer In MIG

    • Short-Circuiting / Dip Transfer

    • Globular Transfer

    • Spray Transfer
    Metal Transfer In MIG
    CS Solid Wire 1.2 mm Φ

    Up to 120A 120 to 250A Above230A

    14 – 22V 16 – 24 V 24 – 35 V

    Dip/Short Circuiting Globular Spray

    Co2 or Ar Co2 or Ar Only Ar / Ar+O2


    Short-Circuiting / Dip Transfer
    • Wire In Contact With Molten Pool 20 to 200 times per
    Second
    • Operates in Low Amps & Volts – Less Deposition
    • Best Suitable for Out of Position Welding
    • Suitable for Welding Thin Sheets
    • Relatively Large opening of Root Can be Welded
    • Less Distortion
    • Best Suitable for Tacking in Set up
    • Prone to Get Lack of Fusion in Between Beads
    Globular Transfer

    • Metal transferred in droplets of Size grater


    than wire diameter
    • Operates in Moderate Amps & Volts –
    Better Deposition
    • Common in Co2 Flux Cored and Solid Wire
    • Suitable for General purpose Welding
    Spray Transfer
    • Metal transferred in multiples of small droplets
    • 100 to 1000 Droplets per Second
    • Metal Spray Axially Directed
    • Electrode Tip Remains pointed
    • Applicable Only With Inert Gas Shielding
    – Not With Co2
    • Operates in Higher Amps & Volts – Higher
    Deposition Rate
    • Not Suitable for Welding in Out of Position.
    • Suitable for Welding Deep Grooves
    Pulsed Spray Welding
    • Power Source Provides Two different Current
    Levels“Background” and “Peak”at regular
    interval
    • “Background” & “Peak” are above and below
    the Average Current
    • Best Suitable for Full Penetration Open Root
    Pass Welding
    • Good Control on Bead Shape and Finish
    Synergic Pulse GMAW
    • Parameters of Pulsed Current (Frequency,
    Amplitude, Duration, Background Current) Related to
    Wire feed Rate
    • One Droplet detaches with each pulse
    • An Electronic Control unit synchronizes wire feed
    Rate with Pulse Parameters
    • Best Suitable for Most Critical Full Penetration Open
    Root Pass Welding
    • Good Control on Open Root penetration, Bead Shape
    and Finish
    GMAW Process Variables
    • Current
    • Voltage
    • Travel Speed
    • Stick Out / Electrode Extension
    • Electrode Inclination
    • Electrode Size
    • Shielding Gas & Flow Rate
    • Welding Position
    Parameter For 1.2 ф FC Wire
    • Current – 200 to 240 A
    • Voltage – 22-24
    • Travel Speed 150 to 250 mm / min
    • Stick Out / Electrode Extension – 15 to 20 mm
    • Electrode Inclination – Back Hand Technique
    • Shielding Gas – Co2, 12 L/Hr
    Parameter For 1.2 ф Solid Wire
    • Current – 180 to 220 A
    • Voltage – 20-22
    • Travel Speed 150 to 200 mm / min
    • Stick Out / Electrode Extension – 10 to 20 mm
    • Electrode Inclination – Back Hand Technique
    • Shielding Gas – Co2 – 12 L/Hr
    Results In Change Of Parameters
    • Increase In Current
    – More deposition, More Penetration, More BM Fusion
    • Increase In Voltage
    – More Weld Bead Width, Less Penetration, Less Reinforcement,
    Excess Spatter
    • Increase In Travel Speed
    – Decrease in Penetration, Decrease in Bead Width,
    • Decrease In Gas Flow rate
    – Results In porosity
    • Long Stick Out / Electrode Extension
    – Excess Weld Deposit With Less Arc intensity, Poor Bead Finish,
    Shallow Penetration
    Common Defects In GMAW
    1. Porosity 2. Spatters
    3. Lack Of Fusion 4. Under Cut
    5. Over Lap 6. Slag
    7. Crack 8. Lack Of Penetration
    9. Burn Through 10. Convex Bead
    11. Unstable Arc 12. Wire Stubbing
    Porosity

    Cause Remedy
    1) Less Mn & Si In Wire 1) Use High Mn & Si Wire
    2) Rusted / Unclean BM / Groove 2) Clean & warm the BM
    3) Rusted wire 3) Replace the Wire
    4) Inadequate Shielding Gas 4) Check & Correct Flow Rate

    Porosity . .
    Spatters
    Cause Remedy
    1) Low Voltage 1) Increase Voltage
    2) Inadequate Inductance 2) Increase Inductance
    3) Rusted BM surface 3) Clean BM surface
    4) Rusted Core wire 4) Replace By Rust Free wire
    5) Quality Of Gas 5) Change Over To Ar + Co2

    Spatters
    • ••
    Lack Of Fusion
    Cause Remedy
    1) Inadequate Current 1) Use Right Current
    2) Inadequate Voltage 2) Use Right Voltage
    3) Wrong Polarity 3) Connect Ele. + Ve
    4) Slow Travel Speed 4) Increase Travel speed
    5) Excessive Oxide On Joint 5) Clean Weld Joint

    Lack Of Fusion
    Undercut

    Cause Remedy
    1) Excess Voltage 1) Reduce Voltage
    2) Excess Current 2) Reduce Current
    3) Improper Torch angle 3) Train & Qualify the Welder
    4) Excess Travel Speed 4) Reduce Travel Speed
    Under cut
    Overlap
    Cause Remedy
    1) Too Long Stick Out 1) Reduce Stick Out

    2) Inadequate Voltage 2) Increase the Voltage

    Overlap
    Slag
    Cause Remedy
    1) Inadequate Cleaning 1) Clean each bead
    2) Inadequate Current 2) Use Right Current
    3) Wrong Torch angle 3) Train / Qualify welder
    4) Improper bead placement 4) Train / Qualify Welder

    Slag
    Crack
    Cause Remedy
    1) Incorrect Wire Chemistry 1) Use Right Wire
    2) Too Small Weld Bead 2) Increase wire Feed
    3) Improper Preheat 3) Preheat Uniformly
    4) Excessive Restrain 4) Post heating or ISR

    crack
    Lack Of Penetration*
    Cause Remedy
    1) Too Narrow Groove Angle 1) Widen The Groove
    2) Inadequate Root opening 2) Increase Root Opening
    3) Too Low Welding current 3) Increase Current
    4) Wrong Torch angle 4) Train / Qualify Welder
    5) Puddle Roll In Front Of Arc 5) Correct Torch Angle
    6) Long Stick Out 6) Reduce Stick Out

    * Applicable to SSFPW

    LOP
    Burn through*
    Cause Remedy
    1) Excess Current 1) Reduce the Current
    2) Excess Root opening 2) Reduce root opening
    3) Inadequate Root face 3) Increase root face
    4) Too Low Travel Speed 4) Increase Speed
    5) Quality Of Gas 5) Use Ar + Co2

    *Applicable to root pass


    Burn trough
    Convex Bead Finish
    Cause Remedy
    1) Low Current 1) Increase Current
    2) Low Voltage 2) Increase Voltage
    3) Low Travel Speed 3) Increase Travel Speed
    4) Low Inductance 4) Increase Inductance
    5) Too Narrow Groove 5) Increase Groove Width

    Uneven bead finish


    Unstable arc

    Cause Remedy
    1) Improper Wire Feed 1) Check Wire Feeder
    2) Improper Gas Flow 2) Check Flow Meter
    3) Twisted Torch Conduit 3) Straighten Torch Cab
    Wire Stubbing

    Cause Remedy
    1) Too Low Voltage 1) Increase Voltage
    2) Too High Inductance 2) Reduce Inductance
    3) Excess Slope 3) Adjust Slope
    4) Too Long Stick Out 4) Reduce Stick Out
    Important Terminology used in
    Critical Welding
    • Preheating
    • Post Heating or Dehydrogenation
    • Intermediate Stress leaving
    • Inter pass Temperature
    • Post Weld Heat Treatment
    What Is Preheating?
    • Heating the base metal along the weld joint to a
    predetermined minimum temperature
    immediately before starting the weld.
    • Heating by Oxy fuel flame or electric resistant coil
    • Heating from opposite side of welding wherever
    possible
    • Temperature to be verified by thermo chalks
    prior to starting the weld
    Why Preheating?
    • Preheating eliminates possible cracking of weld and HAZ
    • Applicable to
    Hardenable low alloy steels of all thickness
    Carbon steels of thickness above 25 mm.
    Restrained welds of all thickness

    • Preheating temperature vary from 75°C to 200°C


    depending on hardenability of material, thickness &
    joint restrain
    How does Preheating Eliminate Crack?

    • Preheating promotes slow cooling of weld and


    HAZ
    • Slow cooling softens or prevents hardening of
    weld and HAZ
    • Soft material not prone to crack even in restrained
    condition
    What Is Post Heating?
    • Raising the pre heating temperature of the weld joint to
    a predetermined temperature range (250° C to 350° C)
    for a minimum period of time (3 Hrs) before the weld
    cools down to room temperature.
    • Post heating performed when welding is completed or
    terminated any time in between.
    • Heating by Oxy fuel flame or electric resistant coil
    • Heating from opposite side of welding wherever possible
    • Temperature verified by thermo chalks during the period
    Why Post Heating?
    • Post heating eliminates possible delayed cracking
    of weld and HAZ
    • Applicable to
    Thicker hardenable low alloy steels
    Restrained hardenable welds of all thickness
    • Post heating temperature and duration depends
    on hardenability of material, thickness & joint
    restrain
    How does Post Heating Eliminate Crack?

    • SMAW introduces hydrogen in weld metal


    • Entrapped hydrogen in weld metal induces
    delayed cracks unless removed before cooling
    to room temperature
    • Retaining the weld at a higher temperature for a
    longer duration allows the hydrogen to come
    out of weld
    What Is Intermediate Stress Relieving?
    • Heat treating a subassembly in a furnace to a
    predetermined cycle immediately on completion of
    critical restrained weld joint / joints without
    allowing the welds to go down the pre heat
    temperature. Rate of heating, Soaking
    temperature, Soaking time and rate of cooling
    depends on material quality and thickness
    • Applicable to
    Highly restrained air hardenable material
    Why Intermediate Stress Relieving?

    • Restrained welds in air hardenable steel highly prone


    to crack on cooling to room temperature.

    • Cracks due to entrapped hydrogen and built in stress

    • Intermediate stress relieving relieves built in stresses


    and entrapped hydrogen making the joint free from
    crack prone
    What Is Inter- Pass Temperature?
    • The temperature of a previously layed weld bead
    immediately before depositing the next bead
    over it
    • Temperature to be verified by thermo chalk prior
    to starting next bead
    • Applicable to
    Stainless Steel
    Carbon Steel & LAS with minimum impact
    Why Inter Pass Temperature?
    • Control on inter pass temperature avoids over
    heating, there by
    Refines the weld metal with fine grains
    Improves the notch toughness properties
    Minimize the loss of alloying elements in
    welds
    Reduces the distortion
    What Is Post Weld Heat Treatment?
    • Heat treating an assembly on completion of all
    applicable welding, in an enclosed furnace with
    controlled heating/cooling rate and soaking at a
    specific temperature for a specific time.
    • Rate of heating, Soaking temperature, Soaking
    time and rate of cooling depends on material
    quality and thickness
    • Applicable to
    All type of CS & LAS
    Why Post Weld Heat Treatment?

    • Welded joints retain internal stresses within the


    structure
    • HAZ of welds remains invariably hardened
    • Post Weld Heat Treatment relieves internal stresses
    and softens HAZ. This reduces the cracking
    tendency of the equipment in service

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