Learning Objectives Aer studying this chapter, you will be able to: @ Contrast the various GMAW metal transfer methods, considering arc characteristics, weld charactetistics, and out-ot-position welds. @ Select the proper arc welding machine, wire feeder, shielding gas, flow rate, contact tube, nozzle size, and welding wire type to produce an acceptable weld @ Contrast the various types of shielding gases used for GMAW, and how they affect the shape and penetration of the completed welds. @ Contrast the self-shielded and gas-shielded methods of FCAW. @ Properly assemble and adjust al the equipment required to produce an acceptable weld using the GMAW and FCAW processes. Correctly prepare metals for welding. Weld using GMAW. Make acceptable welds on all types of joints in all positions using GMAW. @ Weld using FAW. Make acceptable welds 6n all types of joints in the flat and horizontal positions using FCAW. @ Identity the potential safety hazards associated with the GMAW and FCAW processes in a working environment and describe ways of safely dealing with these hazards, @ Be able to pass a safety test on the proper use of the GMAW and FCAW processes. The gas metal arc welding (GMAW) process uses a solid welding wire that is continuously fed into the weld pool. The welding wire is consumed and becomes the filler metal. Flux cored arc welding (FCAW) is very similar to gas metal arc welding. One big difference between GMAW and FCAW is that ECAW uses a ‘welding wire with flux inside the wire. See Chapter 4 for an overview of these proces The growing popularity of GMAW is due to several factors. The continuous development and refinement of constant voltage are power sources and wire feeders has made GMAW more effective to use. Welding using GMAW is easy to learn, especially ifa welder has already learned to weld using a different process. GMAW equip- ment is relatively low in cost. Also, GMAW deposits more weld metal in Ibs/hr (kg/hr) than the shielded metal arcand gas tungsten arc welding processes. The low purchase cost, the ability to weld continuously, and the ability to deposit weld metal faster, make GMAW an attractive choice for welding, GMAW can be used to produce high-quality welds ‘on most metals commonly used in manufacturing, including aluminum, magnesium, stainless steels, carbon and alloy steels, copper, and others. GMAW may also be performed easily in all welding positions. FCAW isa very popular welding method. It has the advantages of both GMAW and SMAW. The advan- tages of GMAW include the ability to weld continu- ously, to deposit weld metal faster, and it is an easy process to learn. The advantages of SMAW include the addition of alloying and fluxing elements in the electrode. FCAW can be done with shielding gas. Gas- shielded FCAW is known as FCAW-G. FCAW can also be done without shielding gas. The flux cored elec- trode creates a protective atmosphere around the weld area. Self-shielded FCAW is known as FCAW-S. 267268 — Modern Welding 9.1 Gas Metal Arc and Flux Cored Arc Welding Principles Gas metal are welding is generally used because it isa quick and easy process that produces quality welds. GMAW is done using solid wire electrodes. FCAW uses flux cored welding wires. See Figure 9-1. A shielding gas or gas mixture must be used with GMAW. GMAW is nearly always performed with direct current electrode positive (DCEP) current. Alter- nating current is not used at this time, but devel- ‘opment work is being done to develop an ac power source for GMAW, Direct current electrode negative (DCEN) is rarely used for gas metal arc welding, but has a limited use for surfacing. A variable polarity wave form is possible with an inverter power supply. The variable wave combines the penetration of DCEP with a higher deposition of DCEN. It can be used on thinner steel and aluminum base metal. For every pound of solid GMAW welding wire used, 92%-98% becomes deposited weld metal. Flux cored arc welding wire is deposited with a wire efficiency of 82%-92%. As a comparison, shielded ‘metal arc welding (SMAW) deposits 60%-70% of the welding wire as weld metal. Some spatter does occur in the GMAW and FCAW processes. Very little stub loss occurs when continuously fed wire is used. There are very thin glass-like islands over the weld bead after gas metal arc welding, No heavy slag is developed because the weld area is shielded by a gas. Wire motion Electrode <—Gas nozzle Gas metal are welding (Guaw) A slag covering is present when FCAW. Some of the flux in the FCAW forms a gas around the weld area. Some of the flux formsa slag that covers the weld. Shielding gas may or may not be used for FCAW. ‘A welder can spend more time on the welding task with a continuously fed wire process. This improves the cost efficiency of GMAW and FCAW. ‘The GMAW process can be adapted to a variety of job requirements by choosing the correct shielding ‘gas, electrode size, and welding parameters. Welding parameters include voltage, travel speed, and wire feed rate. The arc voltage and wire feed rate deter- mines the filler metal transfer method, 9.2 Metal Transfer ‘Metal transfer occurs in using two methods. One is by the short-circuiting method. The second is to transfer metal across the are. Methods of transferring ‘metal across the are include: © Globular transfer. © Spray transfer. © Pulsed spray transfer. 9.2.1 Short-Circuiting GMAW (GMAW-S) Short-circuiting gas metal arcwelding (GMAW-S) is used with relatively low welding currents. Welding current, which is controlled by the wire feed speed, is lower for short-circuiting transfer than for globular Wire motion Shielding gas (used) ienes tube +—Gas nozzle (fused) = + oc Ww Cee 1) econ. yyy Flux cored ar welding (FcAW) Figure 9-1, Cutaway views of GMAW and FCAW gas nozzles and electrodes. Shielding gas is not always used with FCAW. If shielding gas is not used, no nozzle is required.or spray transfer. Globular and spray transfer are covered in the next two headings. Short-circuiting transfer is particularly useful on thin metal sections. Short-circuiting transfer is also useful to fill large root gaps or gaps between poor fitting parts. Short-circuiting transfer can be used in all positions. All position welds are made easily because there is no metal transfer across the are. The ‘weld pool cools and solidifies rapidly using the short- circuiting arc. Short-circuiting transfer results in low heat input into the base metal. Since short-circuiting gas metal arc welding has a low heat input, itis also used to weld thick sections in the overhead or vertical welding position. Refer to Figure 9-2 to see how the short-circuiting arc method deposits metal. The arc is terminated Pinch force’ Shielding Metal short Pinch foro circuits to ‘squeezing weld poo! off droplet Wire nears another short colcuit Figure 9-2. The sequence of metal transfer during the short-circulting transfer method, A—The welding wire short-circuits to the weld pool, B—A magnetic pinch force squeezes off a droplet of molten elactrade metal. C—The wolding arc reignites. D—The electrode nears another short circuit condition and the process repeats ise. reignites Chapter 9 Gas Metal and Flux Cored Arc Welding 269 when the electrode touches the molten weld pool. Surface tension from the weld pool pulls the molten metal from the end of the electrode into the pool. A pinch force around the electrode squeezes the molten end of the electrode. The combined effects of surface tension and the pinch force separate the molten metal and the electrode. This separated portion of the elec- trode flows into the weld pool and flattens out. Once the molten metal from the electrode is sepa- rated from the electrode, the current jumps the gap between the new end of the electrode and the weld pool, reestablishing the are. The continuously fed elec- trode again touches the molten pool and the process repeats. The process of shorting the electrode to the work repeats itself about 20 to 200 times per second, The pinch force, which acts to separate the end of the electrode, is created by current flowing through the electrode. Arc voltage, the slope of the power source, and the circuit resistance determine the strength of the pinch force. These factors—voltage, slope, and resistance—also affect the welding current. Ifa 150A currentis set on the arc welding machine, the amperage may rise rapidly to the maximum output of the machine when the electrode short circuits; that could be 500A or more. An inductance circuit is built into the arc welding machine to control and slow own any rapid rises in current Inductance is the property in an electric circuit that slows down the rate of the current change. Some arc welding machines have an electric coil built in near the welding current transformer coils. See Chapter 5 for a discussion of inductance. The current traveling through an inductance coil creates a magnetic field. This magnetic field creates a current in the welding circuit that is in opposition to the welding current. Increasing inductance in a welding machine slows down the increase of the welding current. Decreasing the inductance increases the rate of change of the welding current. ‘Ceameminane apa when ean is used. The pinch force is so great that the molten ‘metal at the end of the electrode literally explodes. A great deal of spatter occurs in this case. Current does not rise fast enough when foo much inductance is used. The molten end on the electrode is not heated sufficiently. ‘An ideal short-circuiting transfer rate and pinch force can be obtained by properly balancing the induc- tance and slope. Shielding gas also has an effect on short-circuiting transfer, Carbon dioxide (CO,) may be used as a shielding gas for short-ircuiting transfer of carbon and low- alloy steels. CO, produces greater penetration, but creates more spatter than an inert gas used for270 Moder Welding shielding. Mixtures of argon and CO, are often used. ‘They provide a good combination of improved pene- tration with minimal spatter. Stainless steel usually requires a mix of three gases. A typical mixture is 90% helium, 7 1/2% argon, and 2 1/2% CO,. Inert gases must be used on all nonferrous base metals. Nonferrous base metals are those that do not contain iron as the main element. This includes all metals except steels, steel alloys, and cast irons, ‘Adding helium to argon increases the penetration. ‘Argon and heliuim mixtures are used only on nonfer- rous base metals. See Figure 9-3 for the metal deposition rate for the short-circuiting transfer method. Modified Short-Circuiting Transfer Recent advancements in power supply tech- nology have made modification of the short-circu- iting transfer process possible. Power supplies alter or modify the current output of the power supply. ‘An inverter power supply is used for modified short- circuiting transfer. The power supply uses feedback information to determine when to change the current from a low background current to a high peak current and to a near zero current. The result is a lower average current than regular short-circuiting transfer and less heat into the weld joint. Also the spatter from the process is significantly reduced. Different power supply manufacturers have their own names for this modified process. The Lincoln Electric Company calls their process Surface Tension Transfer or STT°. Miller Electric Manufacturing Company calls their process Regulated Metal Deposi- tion RMD™. Figure 9-4 shows the current during a short- circuit cycle of the modified short circuiting transfer process. At point A, the lower background current is flowing. The arc melts the end of the wire and the base metal. Just as the electrode shorts to the base metal at point B, the power supply reduces the current to near GMAW Deposition Rates Caan Metal deposited method Ibsihr Short circuiting 28 Globular a7 Spray 6-12 Puised spray 26 Figure 9-3. The approximate rate at which filer metal is deposited with various GMAW methods. zero. There is noarc. After the short occurs, the current increases. At point, the current is increasing to create the pinch force, which necks down the welding wire. A very important part of this process is that just as the molten end of the electrode is about to separate, the current is again reduced to a very low level at point D. ‘The surface tension of the molten weld pool pulls the molten droplet off the end of the electrode and into the weld pool. There is no high current present when the molten droplet separates from the electrode. This low current prevents the end of the electrode from exploding or creating spatter. ‘After the droplet leaves the end of the electrode, the current increases to the peak current amount. The peak current is shownas point E in Figure 9-4. During this peak current period, the weld pool is very fluid. ‘The high current helps the weld pool flow out to the toe of the weld. Finally, Point F shows a new droplet forming on the end of the electrode, the same as in point A. One complete short-circuit cycle is completed and a new one begins. This process is repeated 20 to 200 times per second. This process introduces less heat into the base metal. Two current settings are used: a peak current and a background current. Peak current is necessary to establish the arc after a short circuit, Background current maintains the arc and is significantly less than the peak current. The average of these two currents is less than the current value set during the standard short-circuiting process covered earlier, 9.2.2 Globular Transfer Globular metal transfer occurs when the welding current is set slightly above the range used for the short-circuiting metal transfer. In the globular metal transfer process, the metal transfers across the arc as large, irregularly shaped drops. See Figure 9-5. The drops are usually larger than the electrode diameter. Drops form on the end of the electrode. Each drop grows so large that it falls from the electrode due to its own weight. If the shielding gas contains a high percentage of inert gas, the drops fall straight into the weld pool. Ifthe shielding gas contains a high percentage of CO, the drops travel across the arc in random paths, creating spatter. To minimize spatter, a shorter arc length can be used. However, too short of an arc length would allow large drops to contact the base metal before the drops separate from the electrode. The resulting short circuits would cause the drops to explode, creating a lot of spatter. ‘One way to minimize spatter when using CO, is to increase the current slightly. This creates a deep weld pool that is lower than the surface of thesurrounding metal. This is referred to as a buried arc or submerged arc. Using a butied are, most of the spatter is contained within the deep weld pool. With a buried are, a combination of globular and short-circu- —Peak current Peak time —>| Pinch current Tall-out speed Background current Figure 9-4, A—Changes in the welding current during a single STT” shor cult, B—High speed photos show what is happening at citferent stages of the STT® modified short-circuiling transfer process. C—An STT diagram (The LincoIn Electric Company) Chapter 9 Gas Metal and Flux Cored Are Welding 271 ing transfer occurs. Deeper penetration occurs when using a buried arc. ‘The globular transfer method can be used to create welds faster than the short-circuiting transfer method. See Figure 9-3 for the rate at which metal is deposited with this transfer. Welds of sufficient quality for many applications can be produced with this transfer method. However, because the molten metal falls into the weld pool due to gravity alone, this method of transfer can be used only in the flat position, 9.2.3 Spray Transfer Spray transfer gas metal arc welding, requires current and voltage settings higher than those required for globular transfer. Spray transfer occurs when very fine droplets of metal form at the tip of Shielding Irregular large droplet ‘forming Droplet may short circuit when it falls Spatter_ Droplet may fall erratically ‘and cause spatter Buried arc helps to contain droplet to reduce spatter Figure 9-5, GMAW globular metal transfer. Drops may fall erratically and cause spatter. Note that the buried arc may help contain the drops to reduce spatter.272 Modern Welding the welding wire, The droplets travel at a high rate of speed directly through the arc stream to the weld pool. Figure 9-6 illustrates the spray transfer method, Spray transfer only takes place when the shielding gas contains a high percentage of argon. To weld nonferrous metals and alloys, use 100% argon shielding gas. A shielding gas mixture containing at least 90% argon is required for spray transfer on carbon or low-alloy steels or stainless steels, Before spray transfer can occur, the welding machine's current setting must be set above the transition current. The transition current varies with the electrode diameter, its composition, and the length of electrode extension. For spray transfer, a higher transition current is required for steel than aluminum, The transition current increases as the electrode diam- eter increases. The transition current decreases as the electrode extends farther from the contact tube. Until Shielaing ‘as. ‘ervelope Wire Metal droplets Stage 2 Figure 9-6. Spray transfer method. Note how the droplets are concentrated in the center of the arc. Spray transfer only ocours when a high percentage of argon gas is used. the transition current is exceeded, the metal transfers as large globules. Above the transition current level, the pinch force becomes great enough to squeeze the ‘metal off the tip of the electrode as fine droplets. See Figure 9-7 for various transition current levels. The droplets are squeezed off cleanly and trans- ferred across the arc gap in a straight path. Spray transfer occurs only when at least 80% argon is used as the shielding gas. Most shielding gas mixtures used for spray transfer have at least 90% argon in the mixture. Common shielding gas mixtures for carbon and low-allay steels are: 98% Ar plus 2% O,; 95% Ar plus 5% 0,;95% Ar plus 5% CO,; and 90% Ar plus 10% CO,, The spray transfer method produces deep pene- tration. The arc can be directed easily by the welder. ‘This is because the arc and metal spray pattern are stable and concentrated. Spray transfer is best done in the flat or horizontal welding position, and on metal over 1/8” (3mm) thick. See Figure 9-3 for the metal deposition rate. 9.2.4 Pulsed Spray Transfer Pulsed spray transfer gas metal arc welding method is similar to the spray transfer method. See Figure 9-8. Electrical control circuits within the power source (welding machine) cause the current to pulse from a low current level to a high current level. There is an arc at the low current level, but no metal transfer takes place. At the high current level, spray transfer droplets leave the electrode and enter the weld pool. Background current is the low-level current. Low current is present to maintain the arc. At regular frequencies, the current is increased to the peak current. The peak current is greater than the transi- tion current level. Since the background current is on for only a short time, no globular transfer actually occurs. During the peak current time period, spray transfer occurs. In this method, the metal leaves the electrode in a spray of small droplets. Since this type of spray transfer does not occur continually, itis called pulsed spray transfer: In pulsed spray transfer, the rate of metal transfer increases and the droplet size decreases as the pulse frequency increases. Basic welding machines with pulse capa- bilities allow the welder to select pulse frequencies of 60 or 120 pulses per second. Some machines allow the user to adjust the pulse frequencies. Pulse frequencies can be set between 30 and up to 400 pulses per second, depending on the manufacturer, A lower average current level is used in pulsed spray than in spray transfer. This lower average current level makes it possible to weld out of position,Chapter9 Gas Metal and Flux Cored Are Welding 273 SMC uS aC US uke cy Minimum spray Wire electrode diameter Shielding gas are current, A inches Mid stoe! 0.030 98% argon-2% oxygen Mid stee! 0.035 98% argon-2% oxygen Mild stee! 0.045; 98% argon-2% oxygen Mild steet 0.062 98% argon-2% oxygen Stainless stee! 0.035, r 99% argon-1% oxygen, Stainless stee! 0.045, ‘99% argon-1% oxygen Stainless tee! 0.062 99% argon-1% oxygen Aluminum 0.030. argon Aluminum 0.045 argon ‘Aluminum 0.062 ‘argon Deoxidized copper 0.035 argon Deoxidized copper 0.045 argon Deoxidized copper 0.062 argon icon bronze 0.035 argon Slicon bronze 0.045 argon Sticon bronze 0.062 argon Noe: Spray rancor wil only occur whan aN perceninge of argon suse Figure 9-7. The Welding Handbook, 8th Edition, Volume 2, Table 4.1, Globular to Spray Transition Currents, reproduced with permission of the American Welding Society, Miami, Fl ‘Thin metal sections may also be welded more easily with the pulsed spray. This transfer method creates very little spatter. Anadvantage of the pulsed spray transfer method is that itcan use larger-diameter welding wire. Larger- s diameter electrodes are cheaper. Also, nonferrous Fe aope roplot wires of a larger diameter can be fed through the wire drive unit more easily without kinking, See Figure 9-3 for the metal deposition rate for the pulsed spray transfer method. One application of pulsed spray is with silicon bronze welding wire. This process is sometimes called GMAW or MIG brazing. The pulsed spray transfer method allows thin steel parts to be brazed with very low heat inputs. Very low heat input from the pulsed spray transfer process reduces distor- tion and melt-through problems. This makes the method well-suited for use in auto body repair shops. Shielding 9.3 GMAW and FCAW Power Sources GMAW and FCAW welding power sources provide a constant voltage. A common type of power source is Figure 9-8. Pulsed spray metal transfer method. Spray _the transformer-rectifier machine. GMAW and most transfer only occurs during peak current. FCAW is done using direct current electrode positive274 Modern Welding (DCEP). Direct current electrode negative (DCEN) can be used in special applications which includes surfacing, Alternating current (ac) is not used for GMAW or FCAW. Inverter power sources are much smaller and lighter than traditional transformer-rectifier machines. This type of power source is gaining in popularity. An inverter can be built for constant voltage for GMAW and FCAW. An inverter may be built for constant current for SMAW and GTAW. Some inverter power supplies are built and can be used for various welding processes. Inverter power supplies that are designed for multiple processes provide a choice of constant current (cc) or constant voltage (cv) from the same machine. The welder must select the constant voltage ‘mode when gas metal arc welding or flux cored arc welding, An inverter machine performs very much like a transformer-rectifier constant voltage machine. ‘Transformer-rectifier machines are designed to control voltage. Voltage is one of the two impor- tant variables used to set the welding parameters for GMAW. On the front of the machine, there is a control that is used to set the voltage. The second important variable is the wire feed speed, Machines used for GMAW and FCAW may have a wire feeder built into the power supply, or the wire feeder may be an external unit, as seen in Figure 9-9. If the wire feeder is built into the power source, the wire or ae ‘Water connections for water-cooled torch Figure 9-9. An inverter power source with a separate wire feeder mounted on top of the welder. (Miller Electic Mfg. Co) feed speed control is on the welding power source. If the wire feeder is not in the power source, the wire feed speed is set on the external wire feeder. When the welder changes the wire feed speed, the welding current changes to adapt to the new wire speed. A higher wire feed speed requires a higher current to ‘melt the welding wire faster. A slower wire feed speed requires less current to melt the welding wire. Inverter machine controls are very similar to those on a transformer-rectifier machine. If the inverter machine has the ability to perform multiple welding processes, select GMAW or the constant voltage setting. After making this selection, set the voltage. The wire feed speed setting determines the wire feed speed and also sets the appropriate current. The output and performance of an inverter are the same as those of a transformer-rectifier type machine. Refer to Chapter 5 for more information on inverter ‘machines, 9.4 Setting Up the GMAW/ FCAW Station Figure 9-10 illustrates a complete GMAW outfit. The same equipment may be used for flux cored are welding. Remember, self-shielding FCAW does not require any shielding gas. ee Procedure for Preparing a GMAW or FCAW Outfit To prepare a GMAW or FCAW outfit for welding, the following steps should be taken: 1, Connect a separate wire feed unit to the welding power source, if required. The ‘manufacturer's instructions should be followed to make these connections. Usually, asingle cable assembly is enough to electri- cally connect the wire feeder to the welding machine. The welding lead from the positive terminal of the welding machine is usually connected to the wire feeder. Connecting the positive lead to the wire feeder provides DCEP current. 2, Mount the desired welding wire reel (spool) onto the wire feeder. See Figure 9-11. 3, Determine what shielding gas is required. See Heading 9.4.3. No shielding gas is required for self-shielded FCAW. Properly secure the cylinder (if used) to prevent it from being knocked over. Check that the regulator and gas flowmeter are attached properly. ConnectChapter 9 Gas Metal and Flux Cored Are Welding 275 witch Wire ree! Wire speed controt Flowmeter | Voltage contro! Gas out sy Regulator Work Contactor cable held gun Wire feed drive motor Contactor control” 1 OV’ supply Figure 9-10. Diagram of a complete gas metal arc welding (GMAW) outfit S Welaing power source Figure 9-11. A welding wire reel on a wire feeder. (The Lincoln Electric Company) a hose from the flowmeter to the welding machine or wire feeder as required. The GMAW and FCAW-G processes require a shielding gas connection. The FCAW-S process does not. Finally, the hose and fittings should be checked to make sure there are no leaks in them. 4. Connect the welding gun to the correct place on the welding machine or wire feeder. Quite often, two connections need to be made. See Figure 9-9, One is the main cable that is connected where the welding wire exits the wire feeder. Attach this part of the cable assembly to its proper place. The second connection is for the electrical contact to the gun trigger. This part of the cable assembly also must be connected to its proper place. ‘water-cooled gun has additional connections. 5. Connect the workpiece lead to the welding ‘machine, Both the welding gun cable assembly and the workpiece lead should be checked for any signs of wear or cuts, Wear or cuts on the outside of these items may indi- cate damage to the leads. 6. The workpiece clamp should be checked. The clamp should be clean so it can make a good electrical connection. 7. Ifa water cooler is used, connect it to the welding machine or to the gun according. to the manufacturers’ recommendations. Usually, the welding machine, wire feeder, or welding gun is connected to the outlet on the water cooler. This way, cool water flows from the cooler to the gun. Warm water returning from the gun is connected to the inlet on the ‘water cooler, When setting up the GMAW or FCAW station, look for all potential safety problems. Spatter from GMAW or FCAW can cause a fire. All flammable materials must be removed from the welding area.276 — Modern Welding 9.4.1 Setting Up a GMAW/FCAW Power Source In order to produce acceptable welds, a GMAW power supply must be properly adjusted for the ‘material being joined and the desired metal transfer method. Before setting up the power source, the following information needs to be known: © The type of base metal to be welded. © Base metal thickness. ‘© The type of transfer method to be used. © The type of shielding gas to be used. © The type and diameter of welding wire. ‘Once this information is known, the welding machine can be properly set up. Only a few controls must be set prior to welding. Figure 9-12 shows a welding machine and its controls. First, adjust the voltage setting, The voltage deter- mines the arc length and helps determine the metal transfer method. Other factors also affect the transfer method, as discussed in Headings 92.1 through 92.4 Second, adjust the wire feed speed. Welding machines with a wire feeder built in have the wire Voltage adjustment — Gun cable connection Ces rem Figure 9-12. A GMAW/FCAW power source. (Miller Electric Mfg. Co.) feed speed control on the machine itself, If the wire feeder is a separate unit, the wire feed speed adjust- ment is on the wire feeder. When the welder adjusts the wire feed speed, he or she is also adjusting the ‘machine's nominal amperage. The following figures list the voltage and amperage settings for welding different base metals using both short-circuiting transfer and spray transfer. Metal Metal Transfer Figure Method No. Mild and low Short circuit 913 alloy steel Spray transfer 9-14 Stainless steel Shortcircuit_ 9-15 (300 series) Spray transfer 9-16 Aluminumand — Spray transfer 9-17 aluminum alloys Copper and Spray transfer 9-18 copper alloys Mild steel FCAW 99 Stainless steel FCAW 9-20 Wire feed adjustment Jog/Purge ‘switch Voltage and current metersGlobular transfer voltages and amperages fall in the range between those shown for short-circuiting and spray transfer. Pulsed spray background voltage settings are slightly higher than the values shown for short-citcuiting transfer. The peak current must be above the transition current. GMAW Short Circuit Transfer — Mild Steel Electrode ‘Arc diameter voltage inches [mm Vv. A ‘Amperage range 0.030 os 0.035, og 0.045 ra 15-21 16-22. 17-22 70-130 80-190 100-225 "Note:The values shown ae basod on tha use of CO, fr mild 6) and 51900 Cp franc see! Figure 9-13. Approximate machine settings for short- circuiting metal transfer on mild and low-alloy steel. CUES MCS eee US) Electrode Arc diameter voltage range hes | mm v A 0.080 08 24-28 150-265 0.035, og 24-28 175-290 0.045 ra 24-30 200-315 116 16 24-32 275-600 9732 24 20-33 350-600 Note:The values shown are based onthe Usa anon wih 2-H oe fori ord cacy se Figure 9-14. Approximate machine settings for spray transfer ‘on mild or low-alloy steel CE eect Umer eee Electrode Arc ‘Amperage diameter voltage range inches [mm Vv. A 0.030 os 17-22 50-145 0.095, oO 17-22 65-175 0.045 rr 17-22 100-210 he shown 2 based on & micro of 0% helm; 7 1% argon 28 CO, Figure 9-15. Approximate machine settings for short- circuiting transfer on 300 series stainless steel Chapter9_ Gas Metal and Flux Cored Arc Welding 277 Figure 9-21 shows a welding machine on which welding variables are set and stored in electronic memory. The welding machine has a microprocessor inside, ‘A microprocessor can be considered a small computer. The manufacturer programs the micropro- cessor with a set of welding values. The micropro- cessor determines the best settings or parameters for the welding application based on a set of input data about a weld. The welding machine determines the welding parameters as well as the type of transfer. TES CU ee eae] Are Amperage diameter voltage range inches [mm v A 0.080 08 24-28 160-210 0.085 09 24-29 480-255 0.045 14 24-30 200-800 1116 16 26-32 215-325, ase 24 24-22 225-375 Note:The vies shown are basea on he ue of agon-oxaan niiing gas, The cnygenpercotage var tam 15% Figure 9-16. Approximate machine settings for spray transfer on 300 series stainless stool Electrode Are ‘Amperage diameter voltage range inches | mm Vv A 0.080 oa 19-22 100-150 0.047 (aie) | 1.3 22-28 130-200 416 16 24-30 180-200 3182 2a 26-34 220-450 Figure 9-17. Approximate machine settings for spray transfer with 100% argon on aluminum and aluminum alloys, Figure 9-18. Approximate machine settings for spray transfer with 100% argon on copper and copper alloys.278 Modern Welding eee scl Electrode diameter ‘Amperage voltage range Inches | _mm Vv A 0.035, os 26-92 180-250 0.045 44 24-28 380-250 0,082 13 24-28 200-850 116 16 25-30 225-875 564 20 26-30 275-450 3/32 24 26-32 350-500 118 32 30-34 400-600 Figure 9-19. Approximate machine settings for FCAW mild steel using an E70T- electrode and CO, shielding ‘gas. Lower values are for out-of-posttion welding. Higher values are for flat and horizontal fillet welding en ees esc Electrode diameter ‘Amperage range inches A 0.035) 90-440 0.085 140-260 is 200-800 Figure 9-20. Approximate machine settings for FCAW stainless steel using CO, shielding gas. When using 75% ‘Argon 25% CO, shielding gas, lower the voltage by 2 volts. Lower values ae for out-of-position welding, Higher values, are for flat and horizontal filet welding, Figure 9-21. A microprocessor-controllod power source with a builtin wire feeder and digital displays. (The Lincoln Electric Co.) ‘A welder using a microprocessor-equipped welding machine enters the following information about the weld to be made: welding wire type, wire diameter, type of shielding gas, and metal thickness. The microprocessor sets the voltage, wire feed speed, and possibly the slope, thus determining the type of metal transfer used, Standard welding values are preprogrammed into the welding machine. Special welding parameters can also be saved as a program in the machine. This program, or any preset values, can be recalled at any time in the future, Because the welding values are stored electronically, the welding ‘machine is set up exactly the same way each time. Some power sources allow the slope to be changed. Many machines have a preset value for the slope. See Chapter 7 for more information on slope. Power sources that have the ability of pulse spray transfer have additional controls to set up. These controls include an on-off switch, a background voltage adjust- ment, a peak amperage adjustment, and sometimes fa “pulses per second” adjustment. The background voltage is set relatively low, in the globular transfer range. The peak amperage is fairly high to cause spray transfer to occur. This peak amperage must be above the transition current. The pulses per second adjust- ment is used to set the number of times per second the current pulses from the low value to the high value. 9.4.2 Setting Up the Wire Feeder Most wire feeders use a T15V ac motor. However, 24V de motors are becoming very popular. Figure 9-22 shows a complete wire drive unit. Two mated gears are located in the wire drive unit, One gear is driven by an electric variable-speed motor. A roll is attached Wire spool spindle Digital amporage readout Digital volage readout Selector ‘euiteh for two preset wire feed conditions, Figure 9-22. A wire feeder with multiple feed control programs. (Thermal Arc, a division of Thermadyne Industries, Inc.)to each gear. Figure 9-23 illustrates a two-toll wire drive system, The lower roll on the wire drive unit shown in Figure 9-23 is adjustable in and out. The lower drive gear has spring washers behind it. By turning the adjustment bolt in the center of this gear, the gear and drive roll can be moved inward or outward. This adjustment is provided to align the groove in the wire drive roll with the center of the wire. Figure 9-24 illus- trates the adjustment of the wire drive rolls. Figure 9-25 shows a wire drive unit with four rolls. In this figure, the pressure rolls have been swung up to their disengaged position to show the alignment of the wire guide with the grooves in the drive rolls. This drive unit is similar to the two roll unit shown in Figure 9-23. The unit shown in Figure 9-25 has three wire guides. Wire guides must be in alignment with each other and with the grooves of the drive rolls. Figure 9-26 illustrates properly and improperly adjusted wire guides. The alignment of the wire guides is made at the factory. Over time, an adjustment may be necessary. The end of each wire guide should be adjusted as close to the drive rolls as possible without touching them. After the wire guide is set, the securing bolt is tightened to hold the guide in place. Wire pressure adjusting kn ees reer —_— Earn rl ene Inend out Pen oa eer Figure 9-23. A two-roll wire drive system. The upper pressure roll can be pivoted out of the way when the wire pressure adjusting knob is released. (Miller Electric Mig. Co.) Chapter 9 Gas Metal and Flux Cored Arc Welding 279 Pressure | roll [Drive roll " Invout A adjustment bolt Welradjusted c rossure roll down far enough Wire too loose: and in alignment agjust pressure roll dovirwvard —=p Ralls missligned: adjust drive rolloutward Figure 9-24. A—A properly adjusted pressure roll. 8—Rolls misaligned. To correct this problem, the lower drive roll is adjusted in and out by means of an adjustment bolt in the Center of the drive roll. C—Wire too loose. To correct this problom, the pressure roll is adjusted up and down by means of the pressure-adjusting wing nut or knob. Wire guides Figure 8-25. A four-roll wire drive system. The parts are similar to a two-roll wire drive. Tho main drive gear is in the center below the two lower rolls. The main gear drives the gears behind the lower rolls. (The Lincoln Electric Co.)280 — Modern Welding Drive roll Inlet wire guide Outlet wire ‘guide Good Diive rolls and wite ‘guides properly aligned Wiro bent down Drive housing and wire ‘guides too high. To correct Tower drive housing Drive Drive housing attaching batts) Wire bent up Drive housing and wire {guides too low. To correct: False drive housing Figure 9-26. Properly and improperly sligned wire guides. If the wire bends going through the drive rolls, adjust the drive housing up or down. Loosen the drive housing bolts, align, and tighten the bolts. ‘One problem that occurs occasionally during wire feeder operation is the wire getting jammed and forming a bird's nest. A bird's nest is a tangle of welding wire that did not feed properly through the rolls and into the guide tube. Figure 9-27 shows such a bird's nest. ‘A bird's nest can be caused by the following conditions: © Stubbing the electrode onto the base metal. ‘This is caused by holding the gun too close to the work, using too-low a voltage or by using too-high a wire feed speed. Figure 9-27. Removing a bird's nest by cutting the welding wire behind the inlet wire guide and before the outlet wire guide. © Misaligned guide tubes and rolls. @ blockage in the cable or liner. ‘To correct the cause of a bird's nest, use the correct contact tube-to-work distance, which will be explained later in the chapter, or adjust the settings on the welding machine or wire feeder. If this does not solve the problem, determine if there is a misalign- ment of the guide tubes and rolls or if there is a blockage in the cable or liner. To eliminate the bird's nest and continue ding, the following steps should be taken: 1. ‘Tum off the power source and the wire feeder. 2, Open the housing to expose the wire feeder mechanism and raise the upper pressure roll(s). 3, Cut the bird’s nest wire at the inlet wire guide and the outlet wire guide, See Figure 9-27. 4, Remove the welding wire from the cable assembly going to the welding gun. This elim- {nates the bird’s nest. 5. Feed new wire into the cable assembly and lower the upper pressure roll(s) 6. Make any necessary adjustment to roll pres~ sure and alignment: 7, Feed the welding wire to the gun by pulling the trigger on the gun, or by pressing the inch jog switch.‘To load a spool of welding wire, remove the spool retainer and the empty spool. Place the new spool onto the hub on the wire feeder, Install the retaining device that holds the spool to the hub. This is usually. a threaded fastener. Some retainers are spring-loaded and can be used to adjust the turning resistance of the spool. The resistance should be set low enough that the spool turns easily when the wire is pulled, but high enough that the spool does not turn by itself if the wire is not being pulled, Wire feeder rolls have one or two grooves cut in them. Select and install rolls that have the same groove diameter as the diameter of the welding wire being used. Remember to change the wire feeder rolls if the electrode diameter changes. The final adjustment is to apply the proper force from the rolls to the electrode. Adjustment is made using a spring-loaded wing nut or knob. Tighten the knob to apply only enough force to drive the wire without slippage. Too much force on the rolls and wire may cause the solid wire to flatten (especially if the wire is aluminum). The application of too much force may crush flux cored electrodes. If the wire is damaged, it does not feed through the wire cable and torch properly. If not enough force is applied to the wire, the rolls slip and do not drive the wire consistently. ‘Once these adjustments have been made, the wire feeder is ready to feed wire continuously. Only the wire feed speed needs to be adjusted to meet the requirements foreach welding job. Adjust the wire feed speed to obtain the amperage and transfer method desired. Chapter 9 Gas Metal and Flux Cored Arc Welding 281. Another feature wire feeders often include is an inch switch or jog switch. This switch is used to feed wire to the gun at a relatively slow speed to prevent inking the wire. Another switch is the purge switch. When the purge switch is pressed, shielding gas will flow. Itwill continue to flow until the purge switch is released. This feature is used to purge any air from the shielding gas lines prior to welding, without wasting welding wire. 9.4.3 Inert Gases and Gas Mixtures Used for GMAW and FCAW-G ‘The gases used in shielding gas mixtures for GMAW are argon (Az), helium (Hi), carbon dioxide (CO.), oxygen (O,), and in some cases, nitrogen (N,). Gases ‘used for FCAW-G of mild, low.alloy and stainless steel include carbon dioxide (CO,), argon (Ar), and oxygen (Q)). Gas metal are welding of mild steel can be done with 100% argon, with 100% carbon dioxide, or various mixtures of these two gases and other shielding gases. ‘There are advantages and disadvantages to be consid- ered when selecting the shielding gas to be used. Shielding gases are commonly delivered in cylin- ders, Shielding gas cylinders can be ordered witha single shielding gas or a premixed shielding gas mixture. Each cylinder is labeled by the supplier with its contents. Ifa gas mixture is used, it can be mixed on site by combining multiple pure gases using a double- or triple- unit gas mixer. See Figure 9-28. Such units allow the secondary gas to be mixed by percentage in with the Primary gas. As an example, consider a 75% argon, 25% Figure 9-28. Two gas mixers. The one on the loft mixes uy ‘oxygen with argon. (Thermco Instrument Corp.) Pp t0 50% CO, with argon. The one on the right mixes up to 10%282 Modern Welding CO, mixture. Argon is the primary gas and the carbon © The type of metal transfer desired: short- dioxide is the secondary gas. The gas mixer unit allows circuiting, globular, spray, or pulsed spray the secondary gas to be added as a percentage to the transfer primary gas, in this case 25%. A knob is used to adjust © The desired bead shape, width, and weld the percentage of the secondary gas. The percentage of penetration, the secondlary gas cannot exceed 50%. © The required welding speed. Each shielding gas and mixture of gases has a © The undercutting tendencies of the gas. different effect on the shape of the bead and the pene- Figures 9-30 and 9-31 list shielding gases to be tration. See Figure 9-29. used with different metals and transfer methods. Factors that must be considered when choosing a. The shielding gases listed for short-circuiting shielding gas are: transfer are also used for globular transfer. Those Argon ‘Argon + Oz Helium Argon Carbon Dioxide ‘Argon + COs Helium Figure 9-29. Bead contours and penetration shapes that occur with various gases and DCEP polarity CS rae tiene mee cooked Metal Shielding gas. ‘Advantages ‘Aluminum, copper, | argon and argon-helium | Argon satisfactory on sheet metal: argon-helium proferred on thicker magnesium, nickel, sheet meta. ‘and their alloys ‘Steel, carbon ‘argon-20-25% CO, _| Suitable for metal less than 1/8” (3mm) thick; high welding speeds without meit through: minimum distortion and spatter; good penetration. argon-60% CO, ‘Suitable for metal greater than 1/8” (mm) thick; minimum spatter; clean weld appearances; good weld poo! control in vertical and overhead positions. coe | Desper penetration faster meng speeds: minkmum cost Stoel, low-alloy | 60-70% helium-25-35% | Minimum reactivity; good toughness: excellent are stability, wetting argon-4-5% CO, characteristics, and bead contour, litle spatter. ‘argon-20-25% CO, _| Fair toughness; excellent are stability; wetting characteristics, and bead contour litle spatter. {90% hellum-7.5% argon- | No effect on corrosion resistance; small heat-affected zone; no undercutting; 2.5% CO, minimum distortion; good are stabil. 00, ad wih gobo ranster also Figure 9-0. Suggested gases and gas mixtures for use with GMAW short-circulting transfer.Metal —_| Shielding gas Chapter9 Gas Metal and Flux Cored Are Welding 283 UES euros kee} Advantages Aluminum argon least spatter. 75% holium- | Suitable for metal 1-3" 25% argon 90% helium 10% argon Suitable for metal up to 3" (76mm) thick; highest heat input ‘Suitable for metal 0.1°-1" (0.25mm-25mm) thick; best metal transfer and are stabilly: (25~76mm) thick; higher heat input than argon, imizes porosity. Copper, nickel, & their alloys argon helium-argon | Higher heat inputs of 50 of thicker base metals, Provides good wetting; good control of weld poo! for thickness up to 1/8” (3mm). 1% and 75% hollum mixtures offset high heat conductivity Magnesium Excellent cleaning action, Reactive metals, (ltanium, Zirconium, tantalum) Good are stability; minimum weld contamination. Inerl gas backing is required to prevent air contamination on back of weld area. Stee!, carbon | argon- 2-5% oxygon Good are stability; produces a more fluid and controllable weld pool; good coalescence: and bead contour, minimizes undercutting; permits higher Speads, compared with argon. Stee, low-alloy Minimizes undercutting; ‘argon- 2% oxygen provides good toughness, Steel, stainless} aryon- 1% oxygen ‘argon- 2% exygan Provides better are stab Figure 9-31, Suggested gases and gas mixtures for use wi gases listed for spray transfer are also used for pulsed spray transfer. Inert gases,suchasargonand helium, arechemically inactive and do not unite with other chemical elements. Carbon dioxide, oxygen, and nitrogen are reactive gases. They mix or react with metals in a weld. Carbon dioxide can be used alone as a shielding gas in both GMAW and FCAW. Other than carbon dioxide, reactive gases are not used alone as shielding gas. The gases and gas mixtures commonly used for GMAW and FCAW-G are discussed in the following paragraphs. For more information, refer to Chapter 7 Argon This gas causes a squeezing (constricting) of the are. Spray transfer occurs when welding current i above the transition current. The results are a high- current-density (concentrated) are, deep penetration, a narrow bead, and almost no spatter. The deep penetra- tion is along the centerline of the weld bead. A cross Good are stability; produces a more fluid and controllable weld pool, good coalescence: and bead contour, minimizes undercutting on heavier stainless steeis. ity, @alescence, and welding speed than 1% oxygen mixture, for thinner stainless steo! materials. ith GMAW spray transfer. section, shown in Figure 9-29 shows this deep, finger- like penetration. Argon ionizes more easily than helium and ionized argon conducts electricity. Therefore, lower are voltages are required for a given arc length. Argon hasa low thermal (heat) conductivity, so it conducts heat through the arc more slowly than helium. Itis an excel- lent choice for use on thin metal. It is also good for out- of position welds because of the low voltages required. Argon is the most common inert gas used for welding nonferrous metals. It is used for all types of metal transfer. When welding steel and steel alloys using spray transfer, use a high percentage of argon, 90% or greater. Pure argon used as a shielding gas on carbon steel can have an erratic arc. Pure argon results in undercutting when the spray transfer method is used. Because this undercutting is not acceptable, argon is usually mixed with small amounts of oxygen or carbon dioxide, Argon is heavier than helium, there- fore, less gas is needed to protect a weld.284 Modern Welding Helium Helium (He) is an inert gas with a high thermal conductivity. It transfers heat through the arc better than argon. Because it transfers so much heat to the ‘weld, helium is used to weld thick metal sections. This {gas is also used to weld metals that conduct heat well Metals such as aluminum, magnesium, and copper conduct heat away from the weld zone rapidly and, therefore, require more heat to be applied to the weld. Because helium does not conduct electricity as well as argon, its use requires higher arc voltages, which creates more spatter. Helium allows filler metal to be deposited at a faster rate than is possible with argon. This gas is often used to weld thicker nonferrous metals. Wider weld beads are produced with helium because of the higher voltages used. Helium is lighter than argon and requires two to three times greater flow to provide an equivalent level of protection. In addition to requiring a greater flow rate that uses more shielding gas, helium is about 10% more expensive than argon. Even though the cost for helium may be greater than that for argon, the bene- fits of helium for the right welding application make helium an excellent ch Carbon Dioxide Carbon dioxide (CO,) gas has a higher thermal (heat) conductivity than argon and requires a higher voltage than argon when used in GMAW and FCAW. Since carbon dioxide (CO,) is heavy, it covers the weld well. Therefore, less gas is needed CO, costs about 80% less than argon. This price difference varies from location to location. Beads made with CO, have a very good contour. The beads are wide and have deep penetration and no undercutting, The arc in a CO, atmosphere is unstable and a great deal of spattering occurs. This is reduced by keeping the arc length short. Deoxidizers like aluminum, ‘manganese, or silicon are often added to filler metal intended for use with CO,, The deoxidizers remove the oxygen from the weld metal. Carbon dioxide is the ‘most common shielding gas for FCAW. Good ventilation is required when using pure CO,, About 7%12% of the CO, becomes dangerous CO (carbon monoxide) in the arc. The amount of CO increases with the arc length. Nitrogen In Europe, nitrogen (N,) is used where helium is not readily available. Mixtures containing nitrogen have been used to weld copper and copper alloys. One commonly used mixture contains 70% argon and 30% nitrogen. Argon-Helium Mixtures of argon and helium help to produce a balance between deep penetration and a stable arc. A mixture of 25% argon and 75% helium gives deeper penetration than 100% argon ges, but with equivalent are stability. Spatter is almost zero when a 75% helium mixture is used. Argon-helium mixtures are used on thick nonferrous sections. Argon-Carbon Dioxide Welding ferrous alloys with spray transfer and an arc shielded by pure argon can be erratic and will often have undercutting at the toe of the weld. Mixing CO, in argon helps stabilize the atc and makes the molten metal in the weld pool more fluid. This helps to eliminate undercutting when carbon steels are ‘welded with the GMAW process using spray transfer, ‘A mixture of 75% argon and 25% carbon dioxide or 80% argon and 20% carbon dioxide can be used when performing flux cored arc welding Argon-Oxygen Argon-oxygen gas mixtures are used on low-alloy, carbon, and stainless steels. A 1%-5% oxygen mixture produces beads with penetration thatis wider and less finger-shaped. The addition of oxygen also improves the weld contour, makes the weld pool more fluid, and eliminates undercutting. Also, oxygen stabilizes the arc and reduces spatter, but causes the metal surface to oxidize slightly. This oxidization generally does not reduce the strength or appearance of the weld to an ‘unacceptable level. If more than 2% oxygen is used with low-alloy steel, a more expensive welding wire with additional deoxidizers must be used. Helium-Argon-Carbon Dioxide ‘A heliumvargon-carbon dioxide shielding gas mixture is used to weld austenitic stainless steel, using the short-circuiting transfer method. The following mixture is often used and produces a low bead: 90% He;7 1/2% Ar;2.1/2% CO, Effect of Shielding Gases in Metal Transfer Shortcircuiting transfer on aluminum and other nonferrous metals and alloys requires an inert shielding gas. Short-circuiting transier on steels is done with CO, or a mixture of argon and CO,, A ‘common mixture is 75% argon, 25% CO, A mixture of helium, argon, and CO, is used to weld stainless steel. Globular transfer on steel base metals can occur with pure CO, or with argon with a high percentage of CO,, With CO, the globules leave the wire in a random way and spatter is high.Spray or pulsed spray transfer on nonferrous base metals requires pure argon or an argon-helium mixture. Spray transfer or pulsed spray on ferrous base metals only occurs in an atmosphere that has a high argon percentage. The following argon mixtures are used when welding low-carbon steels with the spray or pulsed spray transfer method: argon with 2%-5 oxygen (O,), and also argon with 5%~10% CO, ‘Small amounts of oxygen or CO, lower the transi- tion current and help stabilize the are. Oxygen or CO, Chapter 9 Gas Metal and Flux Cored Arc Welding 285 allows the molten metal droplets to leave the electrode ‘more easily. Oxygen or CO, makes the weld pool more fluid, reduces the deep finger-like penetration of a pure argon shielded weld, and reduces undercutting, Figure 9-32 lists shielding gas selections for |AW ona number of metals When flux cored are welding, it is important to use the correct shielding gas with the proper elec- trode. Electrodes are designed to be used with a certain shielding gas or gas mixture. a Shielding Gas Selection for GMAW Metals, Gases % Uses and results ‘Aluminum Ar Good transfer, stable ae, ile spator, Removes oxides. 50%Ar-50%He | Hot aro— V8" to 314” (10mm to 10mm) thickness. Removes oxides. 25%Ar-75%He | Hot ar, less porosty, removes oxides — 1/2"to 1” (18mm to 25mm) He Hotter, more gas; 1/2" (13mm) and up. Removes oxides, Magnesium — | Ar Good cleaning 75%1He25%Ar | Hotter, los porosity, removes oxides. Copper (deox) | 75%He-25%ar | Prefered. Good wating, hot. ie Forthinnor materia, Carbon stest_ | COp Shor circuiting ar: high quaity fon current, out-of poston, medium spate. Globular ae: fast, cheap, spatery, deep ponetation, Ar-2% Op Fast, stale, good bead shape, litle undercut, hid veld pool. ne5e6 O8 75%ke25%002 | Short circutng are: fast, no melt trough, lite distortion and spatter 50%4Ar50%COp | Short circuiting ar: deep penetration, lw spatter Lowalloy steel | Ar-2% Op Removes oxides, eliminates undercut, good properties. High-stength | orsHe-s5%Ar | Short ccuiting are stabe aro, good weting and bead contour sols 5%COp ite spatier Good impacts, 75%AF-25%002 | Short ecuiting ar: same excep ow impact. Stainless steo! | Ari% Op No underouting, Stable ae, tid wold, good shape Ar5% Op More etable ae. 0267 1 Short circuiting arc: smal heatatected zono, no undercut tle warping, 2% COp Nekel,monot | Ar Good wetting — decreases fui incon Arie Stable are on thinner materia EEE Figure 9-32. Shielding gas selections for GMAW of various metals.286 Modern Welding Carbon dioxide is a common shielding gas used for FCAW. The metal transfer method is globular. Some fluxes allow for a spray-like transfer. Argon alone is not used for FCAW. ‘A common gas mixture for FCAW is 75%-80% argon and the remaining balance is CO,. This gas mixture, with the proper electrode, will produce a spray transfer method. Less oxidation of the weld occurs when a gas mixture with high argon is used. 9.4.4 Selecting the Proper Shiel Gas Flow Rate for GMAW and FCAW-G Enough gas must flow to create a straight line (laminar) flow. If too much gas comes out of the nozzle, the gas may become turbulent, Turbulent flow of shielding gas can draw in the atmosphere from around the nozzle area. See Figure 9-33. This causes the weld to become contaminated. A gas lens can be installed in the welding gun to create a steady laminar gas flow. ‘When too little gas flows, the weld area is not properly protected. The weld becomes contaminated and porosity occurs, Too little gas creates a popping sound, spatter occurs, the weld shows porosity, and the bead is discolored. Refer to Figure 9-34 for some suggested gas flow rates for use with various metals and thicknesses. Shielding gas flow rates for FCAW-G are similar to those used for GMAW. Nozzle Contact tube Laminar (straight Set the proper flow rate, using the flowmeter. Flow rates for shielding gas are also dependent on the nozzle size and the distance the nozzle is from the ‘weld area. Adjust the flow rate up or down to obtain a weld properly protected by the shielding gas. The heavier shielding gases like CO, and argon drop away from the weld area if welding is being performed out of position. Therefore, the gas flow rates must be increased for out-of position welding, An increase of 10-20 ef (5-10L/min) is appropriate 9.4.5 Selecting the Correct Gas Nozzles and Contact Tubes ‘The gas nozzle is located at the end of the GMAW or FCAW gun, See Figures 9-35 and 9-36. Itis designed to deliver the shielding gas to the weld area in a smooth, unrestricted flow. The gas nozzle is usually made of copper, which is a very good heat conductor, ‘A copper nozzle resists melting when exposed to the heat generated in the welding operation. The same nozzles are used for FCAW-G and GMAW. The construction of the nozzle end of a GMAW gun is shown in Figure 9-36. Nozzles are available with different exit diam- eters, Welding gun manufacturers normally provide information on the correct nozzle to use for various applications. A general-purpose nozzle is often used and works well for most applications. A variety of nozzlesare shown in Figure 9-37, Some nozzles thread Turbulent 9a flow =, = yyy wy Figure 9-93. Effects of gas flow rate. A—Laminar gas flow is the result ofthe proper gas flow rate. B—Turbulence occurs when the flow rate is too high.Chapter9 Gas Metal and Flux Cored Arc Welding 287 Su ko aa uC nce Thickness Shielding gas flow Metal Shielding gas inches | mm | femme | Limin 116 16 25 2 v8 32 35 16 Aluminum ‘Argon and aluminum | 1/4 63 35 16 alloys 3/8 96 40 19 34 19 80 42 75% He, 25% Ar 116 16 25 12 118 32 25 12 Carbon and 75% Ar, 25% CO, for shor-crcuting transfer towalloy stoots |_4 o, 2 ua 98% Ar, 2% O, for spray transter 318 96 38, 16 3/4 19 50 24 416 16 20 14 ‘Stainless 18 32 80 4 stools 90% He, 75% Ar, 2.5% CO, for short-circuit transter Incluging at 3 Eh i 98% Ar, 2% O, for spray transter nickel alloys Ed 96 35 16 12 127 40 19 116 18 50 24 ‘Argon Magnesium 118 32 50 24 and magne- sium alloys va, 63 60 28 ‘Argon or 75% Ar, 25% He 38 26 60 28 18 82 25 2 Copper and ee 44 63 35 16 ‘Argon of 75% Ar, 25% He 3/8 96 40 19 Figure 9-34. Suggested shielding gas flow rates for GMAW and types of shielding gas to use for various base metals and thicknesses. Flow rates for FCAW steels and stainless steels are similar to those shown in ths table. Gas nozzle Figure 9-35. A GMAW gun. The nozzle on this gun is held in place by tension. (Miller Electric Mfg. Co.)288 Modern Welding, Electrode cable Gun lube Nozzle 7 ion Contact — tube adaptor or diffuser _— Insulator Electrode ‘contact — tube ne Electrode A ecto PERI oz ole entrance A , ae Nome i \ a = : Bectose cortact ibe Figure 9-6. A—A schematic drawing of the nozzie end of a GMAW or FCAW torch. B—An exploded view of a gas-cooled GMAW gun, showing the parts. (Beech & Associates) onto the gun. Other nozzles are designed to slip onto or over a nozzle adaptor and are held by tension Special nozzle shapes are also available for special- ized welding operations, as illustrated in Figure 9-38. Under the nozzle lies the electrode contact tube. A contact tube makes the electrical connection between the welding gun and the electrode. ‘The contact tube is threaded into a part of the gun called a diffuser or an adaptor. See Figure 9-37, Figure 9-37. A number of different GMAW nazzies, contact lubes, and contact tube adaptors. (American Torch Tip Co.) ‘One end of the diffuser or adaptor threads into the welding gun. The other end has threads for installing the contact tube. Diffusers have holes around them to allow shielding gas to escape into the nozzle, Shielding gas exils the end of the nozzle to protect the weld area. Contact tubes, alsocalled contact tips, are available with a variety of inside diameters (ID) and lengths. The contact tube must be designed for the diameter of welding wire being used. The inside diameter of the contact tube is critical because the contact tube must maintain good electrical contact with the welding wire as the wire slides through the tube. Each time the wire diameter is changed, the contact tube must bbe changed so that the ID matches the diameter of the wire Most manufacturers of contact tubes make them in different lengths. Different lengths help obtain different transfer methods. The longest tubes for a gun are usually used for short-circuiting. transfer. When using short-circuiting transfer, the contact tube should be flush with the end of the nozzle or should stick out about 1/16” (6mm) beyond the end of the nozzle. With a long contact tube, minimal resistance heating of the wire takes place. See Figure 9-39, Resistance heating of the electrode takes place after the welding wire exits from the contact tube. The electrode extension distance is the distance over which the electrode is heated. The longer this distance, the more heating takes place, Figure 9-39 shows that a long Figure 9-38. Special GMAW nozzle for spot or tack. weldingShort contact tube Long contact tube Nozzle Weiaing| wire Visible extension extension Welding wire extension Figure 8-39. The length of the contact tube and the amount of electrode extension affects the amount of heating that the welding wire receives. The heating takes place in the length of welding wire that extends from the contact tube. With a long contact tube, there is loss extension and thus, less heating, contact tube minimizes the electrode extension and reduces the resistance heating of the welding wire. A shorter-length contact tube is used for spray transfer, A shorter-length contact tube usually keeps the end of the contact tube inside the end of the nozzle. This allows for a longer electrode extension and allows the welding current to preheat the wire more. Another way to adjust the electrode extension is to use a longer or shorter gas nozzle. A shorter nozzle can be used with short-circuit transfer and a longer nozzle with spray transfer. Flux cored electrodes must be heated to a higher temperature than a solid electrode so that some of the flux vaporizes and creates a shielding atmosphere around the weld. A welding gun used for self-shielded flux cored arc welding can use an extension to guide the wire, The extension does not conduct current from the gun to the electrode. The current is passed to the electrode by the contact tube. After passing through the contact tube, the extension guides the wire in some cases for a few inches. The extension allows for a very long electrode extension and allows the flux cored wire to preheat. Contact tubes wear and must be changed regu- larly. Eight hours of continuous welding with a steel electrode can excessively wear a contact tube, Regular replacement of the contact tube ensures a continuous, good electrical contact with the welding wire. Look at the contact tube occasionally. If the round hole is becoming elongated or if the are appears to be fluctuating while welding, itis time to replace the tube. A fluctuating arc may be due to a worn contact Chapter 9 Gas Metal and Flux Cored Arc Welding 289 tube that does not make consistent contact with the electrode. While arc welding, the inside and outside of the nozzle and the outside of the contact tube can become covered with solidified spatter. Spatter will build up inside the nozzle and block the flow of shielding gas or cause the flow of shielding gas to become turbu- lent. The lack of shielding gas, reduced shielding gas, or gas turbulence can cause weld contamination. Clean spatter out of the nozzles needed to maintain a good flow of shielding gas. A special cleaning reamer can be used to remove solidified spatter from the nozzle. Spatter can be kept from sticking by spraying or dipping thenozzle in a special proprietary antistck compound, 9.4.6 Selecting and Installing a Liner The welding wire travels from the wire feeder to the welding gun ina cable. There is a conduit installed inside the cable, called a liner. The liner protects the cable from the continuous wear of the welding wire. The liner also prevents the welding wire from getting tangled or stuck while traveling through the cable. There are two types of liners. One is a hardened steel wire wound in a tight coil to form a tube. This ‘wound steel liner is used for welding hard materials like steel and stainless steel. See Figure 9-40. The second type of liner is made of Teflon®. Teflon is a type of plastic. It is much softer than the wound steel liner material. Teflon liners are used for welding softer materials, especially aluminum wires. Donot run hard welding wire like steel through a ‘Teflon liner. The hard welding wire will wear through the Teflon liner and then wear through the cable. Soft electrodes should not be run through a steel liner. Fine particles will be scraped from the electrode. The fine particles will plug the liner and prevent proper feeding of the welding wire. Fine metal filings can accumulate in a coiled liner. It is a good idea to occasionally blow compressed air ‘Tigger switch J eaimecton Coiled wire liner Combination gun cable Figure 9-40. A coiled wire liner may be used ina GMAW. cable to guide the welding wire. The wire liner sticking out of this welding gun cable is replaced when worn,290 Modern Welding, through this type of liner to remove these very fine particles. The electrode must not be in the liner when the liner is being blown out. Always point the open end of the liner toward the floor or a trash can when blowing out the liner. Never allow the open end to point toward yourself or any other person. ‘Occasionally, liners get worn or become clogged with fine metal particles. Also, if the liner gets kinked, the welding wire will not feed smoothly. The liner must be replaced when this happens. To replace a liner, or to change from one type to the other, disconnect the gun cable from the wire feeder. Remove the nozzle, contact tip, diffuser, and any setscrews used to keep the liner in place. Then, remove the liner from the gun and cable. Install the new liner. Push it firmly until it bottoms out against the far end of the cable. Secure the liner in place. Most liners are made slightly long and must be trimmed to a specific length. Each manufacturer has directions to follow for this process. Reassemble the welding gun. [Attach the cable to the wire feeder, then refed the wire through the cable and liner to the gun. Some gun and liner manufacturers are making liners thatare installed from the welding gunend and not the wire feed end of the gun cable. This rectuces the time it takes to change the liner which improves efficiency. 9.4.7 Selecting the Correct GMAW or FCAW Welding Wire The welding wire used must match, or be compatible with, the base metal being welded. When following a welding procedure specification, the type of electrode to be used is specified, For most welding in construction or manufacturing, the type of elec- trode will also be specified. Follow all specifications when selecting the proper welding wire. When not welding to a specification, the welder should determine the type of base metal being welded. Determine if GMAW or FCAW will be used. Use the information and charts provided in Chapter 7 and select an appropriate welding wire type. Small-diameter wire usually costs more than large-diameter wire. The rate at which filler metal is deposited when using small-diameter wire makes up for its added cost. Because of the small diameter and the high currents generally used in GMAW and ECAW, small-diameter welding wite is melted more rapidly than large-diameter wire. Small-diameter wire is thus deposited at a much higher rate, ‘Once the correct welding wire is selected it should be loaded in the wire feeder. The correctsize drive wheels must be used in the wire feeder. The wire should be fed through the electrode cable using the inch switch until about 2” to 3” (60mm to 75mm) of wire extend beyond the nozzle. Cut the welding wire 0 that its extension is correct for the type of welding being done. 9.5 Preparing Metal for Welding ‘To produce the highest quality welds, the base metal must be properly prepared. Preparation should be done just prior to welding. The weld joint will be clean and without oxidation. Many weld specifications do not require cleaning. ‘This does not mean welding can be done on contami- nated and oxidized surfaces. Contaminants and oxides can be trapped in the weld bead and produce a poor quality weld. Repair welding may be required on usedl, worn and oxidized metal. Even in these situations, the base metal should be cleaned as best as possible to prepare the metal for welding. Metal surfaces may be cleaned mechanically or chemically. Abrasive cloth or wire brushing may be used on lightly oxidized metals. Any abrasive from grinding should be wiped away prior to welding. Any chemicals ‘used should be properly removed prior to welding, Highly oxidized or pitted or dirty base metals may need to be machined or ground to remove the affected material If the metal being welded is expected to remain oxidized prior to welding, select a welding wire with more deoxidizers. Discuss the application with a ‘welding wire supplier to obtain the best welding wire for the application. Joint designs for gas metal arc and flux cored are welding are similar to those used for shielded metal arc welding. The groove angle used when GMAW or FCAW may be smaller than the angle used when SMAW. See Figure 9-41. This narrower angle is possible for two reasons. The wire diameters used are smaller and GMAW penetrates better than SMAW. A 45° groove angle takes less filler metal to fill than a 75° groove angle, Welding time is also less. Therefore, there are savings in filler metal and weld time. 9.6 Electrode Extension Electrode extension is the amount that the end of the welding wire sticks out beyond the end of the contact tube. See Figure 9-42. This distance is some- times referred to as stickout. ‘A good extension for use with the short-circuit GMAW transfer method is about 1/4” to 1/2" (6mm to 13mm). The correct electrode extension for all other‘SMAW Chapter9 Gas Metal and Flux Cored Arc Welding 291 Figure 9-41. Arc welding beads compared. A—Typical groove angle and weld bead for SMAW. B—Typical groove angle and weld bead for GMAW and FCAW. less. Notice that less filler transfer methods varies between 1/2” and 25mm), An electrode extension used for gas-shielded FCAW may vary from 1/2” to 1 1/2” (13mm to 38mm). The suggested electrode extension for use with self. shielding FCAW is 3/4” to 3.3/4” (19mm to 95mm). Along extension may cause too much filler metal to be deposited with low heating by the arc. This may cause shallow penetration and a high-crowned weld bead shape. In spray transfer if the extension is too short, proper preheating of the welding wire does not occur. In ECAW-S, it is important to have the proper electrode extension. If the welding wire is not prop- erly preheated, the flux will not properly produce the shielding gas necessary to protect the welding area. and 1” (13mm 9.7 Welding Procedures Before beginning to weld, the welding station should be checked for safety. All electrical, gas, and water connections must be checked for tightness. Weldments should be tack welded or secured in fixtures prior to welding, Backing may be needed when complete joint penetration is required. Backing refers to a plate, ring, strip, or other device placed on the root side of the joint to control penetration of the weld. Most are welding processes require the welder to control the arc length, welding speed, and torch or gun angle to obtain a good weld. In GMAW and FCAW, the arc length remains constant and is determined by the arc voltage set on the welding machine. While gas metal is required to fll the groove at B. Welding time is also metal or flux core arc welding, the welder must watch and control the distance from the nozzle or contact tube to the work. See Figure 9-42, By controlling the nozzle-to-work distance, the welder controls the elec- trode extension distance. The welding speed affects the bead width and penetration. A slower weld speed produces a wider bead and deeper penetration. Torch angle also affects the bead width and penetration. The terms forehand, backhand, and perpendicular are used to describe the angles at which the gun may be held in relation to the weld bead. Nozzle Welding Contact, wire tube Nozzle- extansion towork to-work Conact distance distance distance“ Woiding | Base metal Ac length Figure 9-42. Electrode extension distance, Other distances important in GMAW and FCAW are also shown,292 Modern Welding In forehand welding, the tip of the electrode points in the direction of travel. This is often referred to as a push angle or push travel angle. In backhand welding, the electrode tip points away from the direction of travel. This is often called a drag travel angle. Perpen- dicular welding is done with the electrode at a 90° ‘angle to the base metal. This is a travel angle of zero. Figure 9-43 shows the effects of these various angles. The backhand method gives the best penetration. A 25° travel angle forward of perpendicular gives the best penetration in the flat welding position, as shown in Figure 9-43, For the best control of the weld pool, a travel angle of 5°15" forward of perpendicular is preferred for all positions. ‘To start welding, tip the top of the gun 5°15" in the direction of travel. Use an auto darkening helmet or flip the non-auto-darkening helmet down over your eyes. To start the arc, the wire feeder, and the ‘gas, squeeze the trigger on the gun. The wire arcs as soon as it feeds out far enough to touch the metal. No striking or up-and-down motion is required to start the arc, as is required with SMAW. ‘When the weld pool reaches the proper width, move the welding gun forward. Continue to move the gun along the weld, watching the width of the weld pool to maintain a uniform size. Continue at a steady forward Direction of travel aS ~ 25° drag travel angle Direction of travel speed until the end of the weld is reached. A run-off tab may be used to ensure a full-width bead to the end of the weld, Without a run-off tab, the end of the weld may have a crater (depression). This depression can be reduced by moving the electrode to the end of the weld and then back over the completed bead about 1/2” (13mm). At the end of this reverse travel, the trigger switch is released. To shield the end of the ‘weld, hold the gun in position to allow the gas post- flow to protect the weld until it cools. ‘More than one pass may be required to filla weld ‘groove. Each pass should be cleaned before the next pass iS laid. This is generally done with a wire brush or wheel. The glass-like coating on some gas metal arc welds is easily removed. The slag layer on a flux cored are weld is heavier and requires more effort to remove. ‘Out-of-position welds require that leathers be ‘worn, Molten base metal, filler metal, and spatter may fall on the welder. Therefore, a cap, coat, cape, and chaps should be worn to protect against burns, 9.8 Shutting Down the Station When welding is stopped for an extended period, the station should be properly shut down. Direction of travel Figure 9-43. Effects of the welding gun angle on the bead. A—Backhand. B—Perpendicular. C—Forehand. Notice that the backhand angle gives the deepest penetration.Close the valve on the shielding gas cylinder or close the valve on the manifold. Press the purge switch to bleed or drain the shieleing gas from the system. ‘Turn the wire feeder ‘Tum the welding machine off. Neatly coil the cable and hang up the gun. Flat Welding Position ‘The face of a weld made in the flat welding posi- tion should be horizontal or nearly horizontal. The weld axis is also horizontal. See Figure 9-44. Any of the metal transfer methods may be used in the flat welding position. The method used depends on the metal thickness and other factors. Base metal positions and gun angles apply to both GMAW and FCAW. Direction 45° to surface 515" travel angle Weld face horizontal Weld axis horizental Figure 9-44. A filet weld on a lap joint in the flat welding Position. Note the angles used and the deep penetration of the weld. Also, notice that the weld face and axis are horizontal or near-horizontal. Chapter9 Gas Metal and Flux Cored Arc Welding 293 9.9.1 Fillet Weld on a Lap Joint The metal should be set up as shown in Figure 9-44. It should be tack welded about every 3” (75mm). Tack welds hold the pieces in position while the weld is made. ‘To make the fillet weld, the centerline of the elec- trode should be held at about a 45° work angle. The electrode and gun should be tilted between 515° forward from a true vertical position. This is a 5°-15° drag travel angle. When the trigger on the gun is pulled, an are forms, and a C-shaped weld pool is created. Point the electrode more toward the surface if the edge begins to melt too quickly. Adjust the position of the gun to maintain a C-shaped weld pool. Weld at a constant speed. Maintain the weld pool at the same size. With practice, gun angles and travel speed are mastered to produce a uniform width bead with uniform ripples in the weld face, See Figure 9-45. Backtrack over the completed weld for about 1/4" (6mm) when the end of the joint is reached. This movement helps reduce the crater that occurs if the weld is stopped at the end of the joint. No matter what type of weld is made, this same finish movement can be made. A run-off tab can also be used to eliminate the crater at the end of a weld. Backhand welding with a 515° drag travel angle allows for good weld bead control and produces good penetration. When welding on thin base metal, backhand welding can burn through the base metal. Switch to forehand welding on thin metal Figure 9-43 shows that the penetration in fore- hand welding is less than the penetration in back- hand welding. A 5°-15° push travel angle is used. Forehand welding using a push travel angle provides the least penetration. Holding the gun perpendicular to the weld joint gives moderate penetration. Back- hand welding using a drag travel angle provides the greatest penetration. Figure 9-45. Lap joint with uniform weld bead width and ripple spacing.294 Modern Welding Changing from forehand to perpendicular to backhand increases penetration, This applies to all ‘welding joints and positions. 9.9.2 Fillet Weld on an Inside Corner Joint Fillet welds may be made on metal up to 3/8” (10mm) thick without edge groove preparation, This can be done because of the deep penetration possible with the spray transfer method. The work angle should be held at a 45° angle fo each metal surface. If the backhand welding method is used, the electrode and gun are held with a 5°-15° drag travel angle. See Figure 9-46, Figure 9-47 shows a fillet weld made using the travel angle described. ‘The GMAW process can generally be used to ‘weld 1/4” (6mm) beads on each pass. Ifthe weld must be more than 1/4” (6mm) thick, two or more weld passes are required 9.9.3 Groove Weld on a Butt Joint juare-groove welds can be made on metal up to 3/8" (10mm) thick without edge shaping, Butt welds of any thickness can be made using the GMAW process, 518" travel angle 48° from surface pay Direction of travel ji Figure 9-46. A fillet wold on an inside comer joint in the flat welding position. The electrode is 45° from each metal surface. Itis also tipped 5°-15° forward in the direction of, travel Figure 9-47. A completed fillet weld done in the flat position as long as the edges of the metal are properly shaped. The groove angle on a V-groove butt weld can be narrower than the angle used with SMAW. Because of the penetration possible with spray transfer methods, the root face can be larger. The root face should not be increased if using short-circuiting transfer as the penetration is not as great as spray transfer. The root opening can be smaller with GMAW than the opening used for SMAW, Figure 9-48 shows a completed butt weld. ‘When a butt weld is being made, the centerline of the welding wire should be directly over the axis of the weld, A drag travel angle of between 5~-15" is correct for the backhand welding method. See Figure 9-49. ‘Adjusting the travel angle to near zero reduced the penetration. A push travel angle, which is forehand welding, can be used to further reduce or control the penetration on thin metals. ‘A keyhole in the weld pool indicates that complete penetration is occurring. One problem that Figure 9-48. A completed butt weld.518° ravel angle ey ca Figure 9-49. A V-groove weld on a butt joint in the flat welding position. Note the narrow (45°) groove possible with GMAW. may occur in a groove weld made with GMAW is whiskers. Whiskers are lengths of welding wire that stick through the root side of a groove weld. Whiskers ‘occur when the welding wire is advanced ahead of the ‘weld pool The wire goes through the weld root and burns off. The burned-off length is left stuck in the weld. Whiskers can be prevented by slowing the welding speed. They can also be prevented by reducing the wire feed speed. A small weaving motion can be used to keep the wire from getting ahead of the weld pool. 9.9.4 Groove Weld on an Outside Corner Joint ‘An outside comer joint is set up as shown in Figure 9-50. A square- or prepared-groove weld may be used. The electrode angles are the same as those used for welds made on a butt joint. Since groove welds are made on the outside comer joint, whiskers can occu. 9.10 Welding Joints in the Horizontal Welding Position The face of a weld made in the horizontal welding position is vertical or nearly vertical. In the horizontal welding position, the centerline of the weld axis is horizontal or nearly horizontal. See Figure 9-51. Short-circuiting, globular, spray, or pulsed spray transfer methods can be used for welding horizontal fillet welds. Horizontal butt welds are limited to short- circuiting and pulsed spray transfer. Trying to use the globular or spray transfer method results in a weld pool Chapter9 Gas Metal and Flux Cored Are Welding 295 er-t8" direction of travel Direction Figure 9-50. A bevel-groove weld on an outside corner Joint in the flat welding position. Direction 15° travel angle of travel ee 1 1 Weld face is vertical or near-vertcal 45° trom surface Tack weld a Figure 9-51. A fillet weld on a lap joint in the horizontal welding position. In the horizontal welding position, the weld axis is near-horizontal and the face of the weld near-vertical. Centerline of weld axis is near-horizontal that is too large and fluid to manage. Also, metal trans- ferred in globular form will not fall into the weld pool 9.10.1 Fillet Weld on a Lap Joint For practice welds, the metal should be set up and, tack welded as shown in Figure 9-51. The centerline of the electrode should be about 45° to the edge and metal surface. It may point more toward the surface if the edge melts too quickly. Use a backhand, forehand or perpendicular gun angle as necessary based on the ‘metal thickness. Backhand method provides the best penetration. A drag travel angle of 5°-15° provides for ‘good control and penetration. The typical C-shaped ‘weld pool indicates that both the edge and surface are melting properly.296 Modern Welding 9.10.2 Fillet Weld on an Inside Corner or T-Joint Square or prepared-groove welds may be made in the horizontal welding position. The use of a V bevel-, U;, or J-type prepared groove depends on the ‘metal thickness and joint design. The bead width used in GMAW does not have to be as wide for the same thickness as when doing SMAW. This is because the gas metal arc weld penetrates deeper. It does not need bead width and reinforcement to strengthen the weld, ‘The electrode should be held at a 45° work angle. Aiming the wire more toward the vertical surface may improve the bead shape. This helps compensate for the ‘molten metal sag, For the best penetration and weld pool control, use a 5°-15° drag travel angle. On thin metals, use a 5°-15° push travel angle. See Figure 9-52 for gun angles. Figure 9-53 shows a completed weld. 9.10.3 Groove Weld on a Butt Joint or Outside Corner Joint ‘A squate- or prepared-groove weld may be used Figure 9-54 shows a U-groove weld in progress. The suis travel angle 45° work angle Direction Figure 9-52. A filet weld on a T-joint in the horizontal welding position. Note the angles from the metal and in the direction of travel Figure 9-53. A completed filet weld. keyhole Line perpendicular tothe base \ metal sutace recon ee ore faclarge Figure 9-54. AUgioove wkd on abt ithe horizontal welding poston. Note the kaye the oot of the weld. electrode centerline should be directly over the weld line. For best weld pool control, use a 515° drag travel angle. The gun and electrode should also point upward slightly to keep the molten metal from sagging. Short-

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