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Gas Metal Arc Welding (GMAW) Process, and Then Provide an Examination of • Excellent Weld Bead Appearance

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Gas Metal Arc Welding (GMAW) Process, and Then Provide an Examination of • Excellent Weld Bead Appearance Gas Metal Arc Welding Product and Procedure Selection Gas Metal Arc Welding • GMAW has higher electrode efficiencies, usually between The gas metal arc process is dominant today as a 93% and 98%, when compared to other welding processes. joining process among the world’s welding fabrica- tors. Despite its sixty years of history, research and • Higher welder efficiencies and operator factor, when compared development continue to provide improvements to to other open arc welding processes. this process, and the effort has been rewarded with • GMAW is easily adapted for high-speed robotic, hard high quality results. automation and semiautomatic welding applications. This publication’s purpose is to provide the reader • All-position welding capability. with the basic concepts of the gas metal arc welding (GMAW) process, and then provide an examination of • Excellent weld bead appearance. more recent process developments. Additionally, the • Lower hydrogen weld deposit — generally less than reader will find technical data and direction, providing 5 mL/100 g of weld metal. the opportunity to optimize the operation of the GMAW process and all of its variants. • Lower heat input when compared to other welding processes. • A minimum of weld spatter and slag makes weld clean up fast Process Definition and easy. Gas Metal Arc Welding (GMAW), by definition, is an • Less welding fumes when compared to SMAW (Shielded arc welding process which produces the coalescence Metal Arc Welding) and FCAW (Flux-Cored Arc Welding) of metals by heating them with an arc between a con- processes. tinuously fed filler metal electrode and the work. The process uses shielding from an externally supplied gas to protect the molten weld pool. The application Benefits of GMAW of GMAW generally requires DC+ (reverse) polarity to the electrode. • Generally, lower cost per length of weld metal deposited when compared to other open arc welding processes. In non-standard terminology, GMAW is commonly known as MIG (Metal Inert Gas) welding and it is less • Lower cost electrode. commonly known as MAG (Metal Active Gas) welding. • Less distortion with GMAW-P (Pulsed Spray Transfer Mode), In either case, the GMAW process lends itself to weld GMAW-S (Short-Circuit Transfer Mode) and STT™ (Surface a wide range of both solid carbon steel and tubular Tension Transfer™). metal-cored electrodes. The alloy material range for GMAW includes: carbon steel, stainless steel, • Handles poor fit-up with GMAW-S and STT modes. aluminum, magnesium, copper, nickel, silicon • Reduced welding fume generation. bronze and tubular metal-cored surfacing alloys. The GMAW process lends itself to semiautomatic, • Minimal post-weld cleanup. robotic automation and hard automation welding applications. Limitations of GMAW Advantages of GMAW • The lower heat input characteristic of the short-circuiting mode of metal transfer restricts its use to thin materials. The GMAW process enjoys widespread use because of its ability to provide high quality welds, for a wide • The higher heat input axial spray transfer generally restricts its range of ferrous and non-ferrous alloys, at a low price. use to thicker base materials. GMAW also has the following advantages: • The higher heat input mode of axial spray is restricted to flat • The ability to join a wide range of material types and or horizontal welding positions. thicknesses. • The use of argon based shielding gas for axial spray and • Simple equipment components are readily available pulsed spray transfer modes is more expensive than 100% and affordable. carbon dioxide (CO2). GMAW 2 www.lincolnelectric.com Gas Metal Arc Welding Guidelines Editor: Jeff Nadzam, Senior Application Engineer Contributors: Frank Armao, Senior Application Engineer Lisa Byall, Marketing GMAW Products Damian Kotecki, Ph.D., Consumable Research and Development Duane Miller, Design and Engineering Services Important Information on our Website Consumable AWS Certificates: www.lincolnelectric.com/products/certificates/ Material Safety Data Sheets (MSDS): www.lincolnelectric.com/products/msds/ ANSI Z49.1 Safety in Welding and Cutting and Arc Welding Safety Checklist: www.lincolnelectric.com/community/safely/ Request E205 Safety Booklet: www.lincolnelectric.com/pdfs/products/literature/e205.pdf GMAW 3 www.lincolnelectric.com Contents Page History of Gas Metal Arc Welding (GMAW) . .6 Modes of Metal Transfer . .7-10 Short-Circuit Transfer . .7 Globular Transfer . .8 Axial Spray Transfer . .9 Pulsed Spray Transfer . .10 Components of the Welding Arc . .11 Shielding Gases for GMAW . .12-15 Inert Shielding Gases . .12 Reactive Shielding Gases . .12-13 Binary Shielding Gas Blends . .13-14 Ternary Shielding Gas Blends . .14 GMAW Shielding Gas Selection Guide . .15 Effects of Variable . .16-17 Current Density . .16 Electrode Efficiencies . .16 Deposition Rate . .16-17 Electrode Extension and CTWD . .17 Advanced Welding Processes for GMAW . .18-19 Waveform Control Technology™ . .18-19 The Adaptive Loop . .20-21 Advanced Waveform Control Technology . .20 Surface Tension Transfer . .20-21 Tandem GMAW . .22-23 Features of Tandem GMAW . .22 Modes of Metal Transfer for Tandem GMAW . .22-23 Equipment for GMAW . .24-31 The Power Source . .25 The Wire Drive System . .26-27 Special Wire Feeding Considerations . .28-29 Shielding Gas Regulation . .28 Bulk Electrode Packaging . .29 Typical GMAW Systems . .30-31 Semiautomatic GMAW System . .30 Automatic GMAW System . .30 Portable Engine Driven GMAW System . .31 GMAW Torches . .31-33 For Semiautomatic GMAW Welding . .31-32 For Hard and Robotic Automation . .33 GMAW 4 www.lincolnelectric.com Contents Page GMAW of Carbon and Low Alloy Steels . .34-39 Selecting Carbon and Low Alloy Electrodes . .34 Types of GMAW Carbon and Low Alloy Steel Electrodes . .35-36 Mechanical Properties . .36 Chemical Composition . .37 AWS Specifications for Manufacturing GMAW Wires . .38 Selecting Carbon and Low Alloy Electrodes for GMAW . .38-39 GMAW of Stainless Steels . .40-57 Types of Stainless Steels . ..
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