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Metal Inert Gas (MIG)/

Gas Metal Arc Welding (GMAW)

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Gas Metal Arc Welding

The MIG/MAG welding process was initially developed in the
USA in the late 1940s for the welding of aluminum alloys.
The latest EN Welding Standards now refer the process by the
American term GMAW (Gas Metal Arc Welding)
The process uses a continuously fed wire electrode
The weld pool is protected by a separately supplied
shielding gas
The process is classified as a semi-automatic welding
process but may be fully automated

The wire electrode can be either bare/solid wire or flux

cored hollow wire

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MIG/MAG - Principle of operation

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Gas Metal Arc Welding

Advantages

Disadvantages

High productivity

Lack of fusion (dip)

Easily automated

Small range of consumables

All positional (dip & pulse)

Protection on site

Material thickness

Complex equipment

range
Continuous electrode
Wide range of application

Not so portable

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MIG/MAG process variables

Welding current

Increasing welding current

Increase in depth and width
Increase in deposition rate

Polarity

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MIG/MAG process variables

Arc voltage

Increasing arc voltage

Reduced penetration, increased width
Excessive voltage can cause porosity,
spatter and undercut

Travel speed
Increasing travel speed
Reduced penetration and width, undercut

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MAG Welding Variable Parameters

Shielding Gases:
The gasses used in MIG/MAG welding can be either 100% CO2
or Argon + CO2 mixes.
100% CO2: Can not sustain true spray transfer, but gives
very good penetration. The arc is unstable which produces
a lot of spatter and a coarse weld profile.
Argon + CO2 mixes: Argon can sustain spray transfer above
24 volts, and gives a very stable arc with a reduction in
spatter. Argon being a cooler gas produces less penetration
than CO2. Argon in normally mixed with CO2 at a mixture of
between 5-25%

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Gas Metal Arc Welding

Types of Shielding Gas
MIG (Metal Inert Gas)
Inert Gas is required for all non-ferrous alloys (Al, Cu, Ni)
Most common inert gas is Argon
Argon + Helium used to give a hotter arc - better for thicker
joints and alloys with higher thermal conductivity

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MIG/MAG shielding gases

Type of material

Carbon steel

Stainless steel

Aluminium

Shielding gas
CO2 , Ar+(5-20)%CO2

Ar+2%O2

Ar

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MIG/MAG shielding gases

Ar

Ar-He

He

CO2

Argon (Ar):
higher density than air; low thermal conductivity the arc has a
high energy inner cone; good wetting at the toes; low ionisation
potential
Helium (He):
lower density than air; high thermal conductivity uniformly
distributed arc energy; parabolic profile; high ionisation potential
Carbon Dioxide (CO2):
cheap; deep penetration profile; cannot support spray transfer;
poor wetting; high spatter

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MIG/MAG shielding gases

Gases for dip transfer:
CO2: carbon steels only: deep penetration; fast welding speed;
high spatter levels

Ar + up to 25% CO2: carbon and low alloy steels: minimum

spatter; good wetting and bead contour
90% He + 7.5% Ar + 2.5% CO2:stainless steels: minimises
undercut; small HAZ
Ar: Al, Mg, Cu, Ni and their alloys on thin sections
Ar + He mixtures: Al, Mg, Cu, Ni and their alloys on thicker
sections (over 3 mm)

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MIG/MAG shielding gases

Gases for spray transfer
Ar + (5-18)% CO2: carbon steels: minimum spatter; good
wetting and bead contour
Ar + 2% O2: low alloy steels: minimise undercut; provides
good toughness
Ar + 2% O2 or CO2: stainless steels: improved arc stability;
provides good fusion
Ar: Al, Mg, Cu, Ni, Ti and their alloys
Ar + He mixtures: Al, Cu, Ni and their alloys: hotter arc than
pure Ar to offset heat dissipation
Ar + (25-30)% N2: Cu alloys: greater heat input

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Gas Metal Arc Welding

Types of Shielding Gas
MAG (Metal Active Gas)
Active gases used are Oxygen and Carbon Dioxide
Argon with a small % of active gas is required for all steels
(including stainless steels) to ensure a stable arc & good
droplet wetting into the weld pool
Typical active gases are
Ar + 20% CO2

for C-Mn & low alloy steels

Ar + 2% O2

for stainless steels

100% CO2

can be used for C - steels

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MIG/MAG Gas Metal Arc Welding

Electrode
orientation

Penetration

Deep

Moderate Shallow

Excess weld metal Maximum Moderate Minimum

Undercut

Severe Moderate Minimum

Electrode extension
Increased extension

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MIG / MAG - self-regulating arc

Stable condition

Sudden change in gun position

Arc length L = 12,7 mm
Arc voltage = 29V
Welding current = 220A
WFS = 6,4 m/min
Melt off rate = 5,6
m/min

Arc length L = 6,4 mm

Arc voltage = 24V
Welding current = 250A
WFS = 6,4 m/min
Melt off rate = 6,4 m/min

19 mm

25 mm

Voltage (V)

Current (A)

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MIG/MAG - self-regulating arc

Re-established stable condition

Sudden change in gun position

Arc length L = 12,7 mm
Arc voltage = 29V
Welding current = 220A
WFS = 6,4 m/min
Melt off rate = 5,6 m/min

Arc length L = 6,4 mm

Arc voltage = 24V
Welding current = 250A
WFS = 6,4 m/min
Melt off rate = 6,4 m/min

25 mm

25 mm

Voltage (V)

Current (A)

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Terminating the arc

Crater fill
Burnback time
delayed current cut-off to prevent wire freeze
in the weld end crater
depends on WFS (set as short as possible!)

Contact tip
3 mm
8 mm

Current - 250A

14 mm
Insulatin
g slag
Burnback time 0.05 sec
Workpiece

0.10 sec

0.15 sec

Voltage - 27V
WFS - 7,8 m/min

Wire diam. - 1,2 mm

Shielding gas Ar+18%CO2

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MIG/MAG - metal transfer modes

Contact tip
extension
(0-3,2 mm)

Electrode
extension
6-13 mm

Set-up for dip transfer

Contact tip
recessed
(3-5 mm)

Electrode
extension
19-25 mm

Set-up for spray transfer

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Gas Metal Arc Welding

MODES OF METAL TRANSFER
The current and voltage settings determine the way molten
droplets of weld metal transfer from the tip of the wire to the
weld pool
There are 3 principle modes of droplet transfer, namely
dip transfer (short-circuiting)

spray transfer
pulsed transfer

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MIG/MAG - metal transfer modes

Electrode diameter = 1,2 mm

Voltage

WFS = 8,3 m/min

Current = 295 A
Voltage = 28V

Globular
transfer

Spray
transfer
Electrode diameter = 1,2 mm

WFS = 3,2 m/min

Current = 145 A

Dip transfer

Voltage = 18-20V

Current

Current/voltage conditions

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Gas Metal Arc Welding

Dip Transfer
Dip transfer occurs when current & voltage settings are low
(typically < ~ 200amps & ~ 22volts)
There is just enough energy to give an arc and cause fusion
at the tip of the wire
A droplet grows to a size larger than the wire diameter and
eventually extinguishes the arc - causing a short-circuit
The short circuit causes the current rises very quickly giving
energy to violently pinch-off the droplet
This is akin to blowing a fuse and causes spatter
When the droplet detaches, the arc is re-established and the
current falls
This cycle occurs at up to ~ 200 times per second

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MIG/MAG-methods of metal transfer

Dip transfer
Transfer occur due to short circuits
between wire and weld pool, high
level of spatter, need inductance
control to limit current raise
Can use pure CO2 or Ar- CO2
mixtures as shielding gas
Metal transfer occur when arc is
extinguished
Requires low welding current/arc
voltage, a low heat input process.
Resulting in low residual stress
and distortion
Used for thin materials and all
position welds

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Gas Metal Arc Welding

Dip Transfer
Transfer-mode advantages

The low energy conditions allow welding in all positions

It can be used for putting in the root run on single-sided
welds

It can be used for welding thin materials

Transfer-mode disadvantages
It frequently gives lack of fusion and may not be allowed in
semi-automatic mode for high-integrity applications
It tends to give spatter
(this can be reduced/controlled by having an inductance
control on the power source)

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Gas Metal Arc Welding

Spray Transfer
When current & voltage are raised together higher energy is
available for fusion (typically > ~ 25 volts & ~ 250 amps)

This causes a fine droplets of weld metal to be sprayed from

the tip of the wire into the weld pool
Transfer-mode advantages
High energy gives good fusion
High rates of weld metal deposition are given
These characteristics make it suitable for welding thicker
joints

Transfer-mode disadvantages
It cannot be used for positional welding

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MIG/MAG-methods of metal transfer

Spray transfer
Transfer occur due to pinch
effect NO contact between wire
and weld pool!
Requires argon-rich shielding
gas
Metal transfer occur in small
droplets, a large volume weld
pool
Requires high welding
current/arc voltage, a high heat
input process. Resulting in high
residual stress and distortion
Used for thick materials and
flat/horizontal position welds

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MIG/MAG-methods of metal transfer

Pulsed transfer
Controlled metal transfer, one droplet per pulse,
No transfer between droplet and weld pool!
Requires special power sources
Metal transfer occur in small droplets (diameter equal
to that of electrode)
Requires moderate welding current/arc voltage, a
reduced heat input . Resulting in smaller residual
stress and distortion compared to spray transfer
Pulse frequency controls the volume of weld pool,
used for root runs and out of position welds

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MIG/MAG - metal transfer modes

Pulsed transfer

Controlled metal transfer. one droplet

per pulse. NO transfer during
background current!
Requires special power sources
Metal transfer occur in small droplets
(diameter equal to that of electrode)
Requires moderate welding current/arc voltage, reduced
heat input smaller residual stress and distortions
compared to spray transfer
Pulse frequency controls the volume of weld pool, used
for root runs and out of position welds

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Gas Metal Arc Welding

Pulsed Transfer
Transfer-mode advantages
Good fusion
Small weld pool allows all-position welding

Transfer-mode disadvantages
More complex & expensive power source
Difficult to set parameters - requires power source
manufacturer to provide pulse programmes to suit wire type,
dia. and type of gas

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MIG/MAG-methods of metal transfer

Globular transfer
Transfer occur due to gravity or
short circuits between drops and
weld pool
Requires CO2 shielding gas
Metal transfer occur in large drops
(diameter larger than that of
electrode) hence severe spatter
Requires high welding current/arc
voltage, a high heat input process.
Resulting in high residual stress
and distortion
Non desired mode of transfer!

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Gas Metal Arc Welding

Dip Transfer: (Voltage < 22) / (Amperage < 200)
Thin materials positional welding

Globular Transfer: Between Dip & Spray Transfer

Limited commercial, Used only in some mechanized MAG

process using CO2 shielding gas

Spray Transfer: (Voltage > 27) / (Amperage > 220)
Thicker materials, limited to flat welding positions, high

deposition
Pulse Transfer: Both spray and dip transfer in
one mode of operation, frequency range 50-300

pulses/second
Positional welding and root runs

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MAG Welding Variable Parameters

Inductance:
Applicable to MIG/MAG process in dip transfer mode.

The electrode is fed slowly through the arc until it

touches the weld pool, at this point the output from

the power supply is short circuited and a very high
current flows through the electrode. If this was
allowed to continue, the wire would melt and eject
excessive amounts of spatter.
The inclusion or the choke in the welding circuit

controls the rate at which the current rises so that the

electrode tip is melted uniformly without excessive
spatter

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The effect of inductance

Maximum inductance
Hotter arc, more
penetration
reduced spatter
More fluid weld pool, flatter
and smoother weld
Recommended on thicker
materials and stainless
steels

Minimum inductance
Colder arc, used only for arc
stability when welding wide
gaps
Convex weld, more spatter
Improved weld pool control
Recommended on thin
materials

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ARC CHARACTERISTICS
Constant Voltage Characteristic
Small change in voltage =
large change in amperage

OCV
Large arc gap
Small arc gap

The self
adjusting arc.

Volts

Amps

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Flat or Constant Voltage

Characteristic
Flat or Constant Voltage Characteristic Used With
MIG/MAG, ESW & SAW < 1000 amps
O.C.V. Arc Voltage
Virtually no Change.

33
32
31

Voltage

Small Voltage
Change.

Large Current Change

100

Amperage

200

300

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MIG/MAG welding gun assembly

Gas
diffuser

Contact
tip

The Push-Pull gun

Union nut

Gas
nozzle

Trigger
Handle

WFS remote
control
potentiometer

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MAG Welding Variable Parameters

Wire feed speed:
Increasing the wire feed speed automatically increases the
current in the wire

Voltage:
The voltage is the most important setting in the spray transfer
mode, as it controls the arc length. In dip transfer it controls
the rise in current

Current:
The current is automatically increased as the wire feed is
increased. Current mainly affects penetration

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Gas Metal Arc Welding

PROCESS CHARACTERISTICS

Requires a constant voltage power source, gas supply, wire

feeder, welding torch/gun and hose package
Wire is fed continuously through the conduit and is burnt-off
at a rate that maintains a constant arc length/arc voltage
Wire feed speed is directly related to burn-off rate
Wire burn-off rate is directly related to current

When the welder holds the welding gun the process is said
to be a semi-automatic process
The process can be mechanised and also automated

In Europe the process is usually called MIG or MAG

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Gas Metal Arc Welding

Types of Filler Wire
Filler wires have similar composition to the base material
Wires can be solid, flux cored or metal cored
Flux cored wires are designed to run in spray mode and therefore
they give good fusion
Flux cored wires cannot be used for root runs on unbacked joints
The slag formed from flux cored wire enables welding to be done in
all-positions
Most flux cored wires have a folded seam that can allow moisture to
get into the flux
Controlled storage & handling is required for seamed wires
Metal cored wires have the same general characteristics as solid
wires - they can be operated in dip or spray mode
Some flux cored wires do not require a gas shield (Innershield)

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Checks when MAG Welding

The welding equipment
A visual check should be made on the equipment
to ensure it is in good working order
The electrodes

The diameter, specification and the quality of the

wire are essential for inspection. The level of
deoxidisation in the wire, single, double or triple
de-oxidised. The quality of the wire winding and
the copper coating should also be inspected to
minimize wire feed problems.

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Checks when MAG Welding

Wire liner
Check that the liner is the correct type and size for the
wire being used. Steel liners for steel and Teflon liners
for aluminium.
Contact tips
Check the tip is the correct size for the wire being
used and check the amount of wear. Excessive wear
will affect wire speed and electrical current pick-up
Gas and gas flow-rates
Type of gas and the flow rate need to be checked to
ensure they comply with the WPS
Other welding variables
Check WFS, amps, volts and travel speed

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MIG/MAG typical defects

Most welding imperfections in MIG/MAG are caused by lack of
welder skill, or incorrect settings of the equipment
Worn contact tips will cause poor power pick up, or transfer

Bad power connections will cause a loss of voltage in the arc

Silica inclusions (in Fe steels) due to poor inter-run cleaning
Lack of fusion (primarily with dip transfer)
Porosity (from loss of gas shield on site etc)
Solidification problems (cracking, centerline pipes, crater
pipes) especially on deep narrow welds