Result and Discussion.

In the process of Gas Metal Arc Welding (GMAW), there some common defect can occur in which probably the same as other welding defects that occur in other welding process. As for the fillet project using the GMAW, a example of defect happened during the welding. Below shows an example of the welding defects that can be seen during the fillet welding process. Porosity:

Figure 1

Usually, shielding gas protects the molten weld pool from the surrounding atmosphere, which would otherwise contaminate the weld. Figure 1 shows how the lack of shielding gas on steel can cause porosity (pinholes) in the weld bead are formed in the face and weld interior in the absence of shielding gas. Lack of shielding gas can be caused by improper setting on the equipment, a hole in the gun liner or wind blowing the shielding gas away.

For this project and the production of the sample for the fillet welding for GMAW process, manual seting is applied to the parameters thus can effect the condition of the final weld produce. When manually setting the parameters there are certain things that need to be look out for so that the weld produced is good and satisfied which are: 1. Voltage to high

Figure 2

Based on the figure 2, too much voltage can cause poor arc control, inconsistent penetration, and a turbulent weld pool that fails to consistently penetrate the base material.

2. Voltage to low.

Figure 3

Based from the figure 3, too little voltage results in poor arc starts, control and penetration. It also causes excessive spatter, a convex bead profile, and poor tie-in at the toes of the weld. 3. Wire feed / amperage to high .

Figure 4

Based on the figure 4, setting the wire feed speed or amperage too high depending on what type of machine you're using can cause poor arc starts and lead to an excessively wide weld bead, burn-through and distortion.

Figure 5

Based on the figure 5, a narrow and oftentimes convex bead with poor tie-in at the toes of the weld is caused by insufficient amperage.

Operators are under complete control of travel speed and gun angle, so they can affect welding results with variations in their individual techniques. Other than setting manually for the machine parameters, the defect and imperfection of the weld also can be cause by the operator issues which can be exampled by: 1. Travel speed to fast:

Figure 6

Based on the figure 6, narrow convex beads with inadequate tie-in at the toes of the weld, insufficient penetration and an inconsistent weld bead are caused by travelling too fast. 2. Travel speed to slow.

Figure 7

Based on the figure 7, travel speed to slow produced too much heat into the weld, resulting in an excessively wide weld bead and poor penetration. On thinner material, it may also cause burn through.

Solution that needs to be taken to overcome the operator issues will be no other than practice. With practice and good equipment care, many welders reach a point at which their technique and welding equipment enable them to create perfect welds on the first pass. Until that time comes, however, sound knowledge of troubleshooting steps can help operators ascertain equipment issues quickly or correct technique errors after the weld. One sure way to shortcircuit the troubleshooting process, however, is to practice the weld on scrap metal taking note of welding parameters and travel speed, access to the weld and the ability to make needed position changes, in addition to weld appearance.