Table 22-7(Concluded)
Problem
C. Porosity in the weld deposit.
D.Welding electrode wire stubs
into workpiece.
E.Excessive spatter while
welding.
F.Weld bead appearance indicates
need for more amperage and/or
larger bead.
G.Weld bead appearance indicates
need for less amperage and/or
smaller bead.
Source: Miller Electric Manufacturing Co.
730 Chapter 22 Gas Metal Arc Welding Practice with Solid and Metal Core Wire: Jobs 22-J1J23 (Plate)
Probable Cause
1. Dirty base metal; heavy oxides, mill scale.
2. Gas cylinder and distribution system.
a) Gas cylinder valve off.
b) Regulator diaphragm defective.
c) Flowmeter cracked or broken.
d) Gas supply hose connections loose.
e) Gas supply hose leaks.
f) Insufficient shielding gas flow.
g) Moisture in shielding gas.
h) Freezing of carbon dioxide regulator/
flowmeter.
3. Wire-feeder control.
a) Gas solenoid defective.
b) Gas hose connections loose.
4. Gun and casing assembly.
a) Gun body and/or accessories aspirating
atmosphere or air.
b) Check O-rings on quick connect type guns.
c) Contact tube extended too far.
d) Nozzle-to-work distance too great.
e) Improper gun angles.
f) Welding speed too fast.
g) Electrode not centered in nozzle.
h) Air turbulence.
5. Improper electrode wire composition.
1. Power source.
a) Excessive slope numerical values set.
b) Arc voltage too low.
c) Excessive inductance value set.
2. Wire-feeder control.
a) Excess wire-feed speed.
1. Shielding gas system.
a) Excessive gas flow rates.
b) Insufficient gas flow.
2. Power source.
a) Excessive arc voltage.
b) Insufficient slope setting value.
c) Insufficient inductance setting value.
3. Gun contact tube recessed in nozzle too far.
4. Improper electrode, shielding gas
combination.
1. Power source.
a) Volt-ampere condition too low.
1. Power source.
a) Volt-ampere condition too high.
Possible Remedy
1. Clean base metal before welding.
2. Gas cylinder and distribution system.
a) Turn cylinder valve on.
b) Replace diaphragm or regulator.
c) Replace and repair.
d) Tighten fittings.
e) Repair or replace.
f) Increase flow rate of gas.
g) Replace gas cylinder or supply.
h) Thaw unit; install gas line heater.
3. Wire-feeder control.
a) Replace solenoid.
b) Tighten connections.
4. Gun and casing assembly.
a) Test; replace or repair faulty units.
b) Replace defective O-rings.
c) Distance from nozzle end maximum 18in.
d) Should be as recommended by equipment
manufacturer.
e) Use correct travel angle; approximately
15 angle.
f) Adjust welding condition for slower speed.
g) Adjust contact tube, nozzle, and wire.
h) Set up wind screen.
5. Obtain and use correct electrode wire.
1. Power source.
a) Reduce slope settings as required.
b) Increase voltage at power source.
c) Reduce inductance setting as required.
2. Wire-feeder control.
a) Reduce wire-feed speed rate.
1. Shielding gas system.
a) Adjust gas flow rate as required.
b) Adjust gas flow rate as required.
2. Power source.
a) Reduce voltage at power source.
b) Increase slope setting as required.
c) Increase inductance setting as required.
3. Replace contact tube with longer one.
4. Obtain and use correct electrode wire, shielding
gas combination.
1. Power source.
a) Increase voltage slowly with applicable in-
crease in wire feed.
1. Power source.
a) Reduce voltage and wire feed as required.

Fig. 22-20 GMAW root pass 2G short circuit transfer on 38-inch thick plate.
Note the excellent penetration and fusion and no whiskers protruding on the
back side of this test piece. Edward R. Bohnart
stable arc, improves the flow of weld metal, and reduces
the tendency to undercut.
Argon with 10 percent CO2 is sometimes used. With
100 percent carbon dioxide, the arc is not a true spray arc.
For short arc welding of carbon steel, a mixture of 75 per-
cent argon and 25 percent carbon dioxide may be used.
Straight carbon dioxide is popular for MAG small wire
welding.
Code welding requires great care in its application.
Good fusion and a minimum of porosity are necessary.
The following precautions should be observed when
doing the practice jobs, Fig. 22-21:
Avoid excessive current values. If the current seems to
be too high and cannot be reduced without affecting the
transfer of metal, switch to a larger size wire.
Fig. 22-21 GMAW final passes short circuit transfer on 38-inch thick plate.
Groove angle 60, SG-AC-25, and 0.035 wire diameter. Note the complete
fusion, uniform bead width, location, and the ripple pattern created by the slight
whipping motion. Edward R. Bohnart
Gas Metal Arc Welding Practice with Solid and Metal Core Wire: Jobs 22-J1J23 (Plate) Chapter 22 731
Check your welding speed. Welding speeds
that are too high cause porosity, and speeds
that are too slow may cause an incomplete
fusion.
Make sure that the gas flow is adequate. The
entire weld area must have the protection of
the gaseous shield.
Keep the wire location centered in the gas
pattern and in the center of the joint. Make
sure that the correct electrode angle is main-
tained at all times.
S
 elect the proper filler wire for material
being welded and for such special situations
as rust, scale, and excessive oxygen.
W
 hen welding from both sides of the plate,
be sure that the root pass on the first side
is deeply penetrated by the root pass on the
second side. Backgouge to sound metal as
required.
For video of GMAW troubleshooting, please visit
www.mhhe.com/welding.
Fillet Welds: Jobs 22-J3J10 Fillet welds are used in T-
joints, lap joints, and corner joints. Much of the welding
done with the gas metal arc process is fillet welding. The
deposit rate and rate of travel are high, and there is deep
penetration. Since the strength of a fillet weld depends on
the throat area, the deep penetration that gas metal arc
welding provides permits smaller fillet welds than is pos-
sible with stick electrode welding.
The position of the nozzle and the speed of welding
are important. You must make sure that penetration is se-
cured at the root of the weld in order to take advantage
of the deep penetration characteristics. The welding tech-
nique should provide protection for the vertical
plate to avoid undercutting. Many of the skills
learned in making fillet welds with stick elec-
trodes and the TIG process can be applied to
MAG welding.
Welding may be single pass or multipass,
depending on the requirements of the job. Mul-
tipass welding may be done with weave beads
or stringer beads, Fig. 22-22. The sequence of
weld passes is the same as that used with stick
electrodes. Each pass must be cleaned carefully.
In making each pass, fusion must be secured
with the underneath pass and the surface of the
plate. Review the precautions listed previously
for groove welds.

Fig. 22-22 A 3F vertical-up fillet weld using GMAW short circuit
transfer. SG-AC-25 with 0.035 wire root pass was stringer. Note the
uniform ripple pattern, uniform width, and minimal spatter on this
as-welded 38-inch weld. Edward R. Bohnart
Inspection and Testing After each weld has been com-
pleted, use the same inspection and testing methods that
you have used in previous welding practice. Look for
surface defects. Keep in mind that it is important to have
good appearance and uniform weld contour. These char-
acteristics usually indicate that the weld was made prop-
erly and that the weld metal is sound throughout. Observe
the appearance of the welds shown in Figs. 22-23 through
22-29, page 734.
Butt joint in the horizontal position Fig. 22-19A
and 19B.
Tee joint in the vertical position Fig. 22-19C
JO B TI P
Salary
When negotiating a salary with a new
employer, avoid disclosing what you made in your last
job. Many businesses decide what your salary will be by
knowing your last pay rate. Instead, say what range you
are expecting.
732 Chapter 22 Gas Metal Arc Welding Practice with Solid and Metal Core Wire: Jobs 22-J1J23 (Plate)
Corner joint in the flat position: Figs. 22-23 and22-24
Lap joint in the horizontal position: Fig. 22-25
Lap joint in the vertical position; direction of travel,
down: Fig. 22-26
T-joint in the horizontal position: Fig. 22-27
Beveled-butt joint in the flat position; no backing bar;
Figs. 22-28 and 22-29. Note that penetration must be
secured through the back side in open root joints like that
required when welding with other processes.
To determine the soundness of your welds, test lap, T-,
and butt joints in the usual manner.
Fillet and Groove Welding Combination Project: Job
Qualification Test 1 This combination test project will
allow you to demonstrate your ability to read a drawing,
develop a bill of materials (SI conversions are optional),
thermally cut, fit components together, tack, and weld a
carbon steel project. You will be using the techniques de-
veloped in Jobs 22-J1 through J10 using the short-circuit-
ing mode of metal transfer. Follow the instructions found
in the notes on Fig. 22-30 (p. 735).
Inspection and Testing After the project has been tacked,
have it inspected for compliance to the drawing. On mul-
tiple-pass welds, have your instructor inspect after each
weld unless otherwise instructed. Use the following ac-
ceptance criteria to judge your welds. Look for surface
defects. Keep in mind that it is important to have good
appearance and uniform weld contour. These character-
istics usually indicate that the weld was made properly
and that the weld metal is sound throughout. Only visual
inspection will be used on this test project to the following
acceptance requirements:
There shall be no cracks or incomplete fusion.
There shall be no incomplete joint penetration in
groove welds except as permitted for partial joint pen-
etration groove welds.
Your instructor shall examine the weld for acceptable
appearance and shall be satisfied that the welder is
skilled in using the process and procedure specified
for the test.
Undercut shall not exceed the lesser of 10 percent of
the base metal thickness or 132 inch.
Where visual examination is the only criterion for ac-
ceptance, all weld passes are subject to visual exami-
nation, at the discretion of your instructor.
The frequency of porosity shall not exceed one in each
4 inches of weld length, and the maximum diameter
shall not exceed 332 inch.
Welds shall be free from overlap.
Only minimal weld spatter shall be accepted, as
viewed prior to cleaning.
Fig. 22-23 Outside corner joint in steel plate welded with the gas metal arc
welding process in the flat position.

Fig. 22-24 Penetration through the back side of a corner joint welded in the
flat position.

Fig. 22-26 Fillet weld on a lap joint in steel plate

welded with the gas metal arc welding process in the 3F
position, downhill. Note the porosity caused by poor gas
shielding.

Fig. 22-25 Fillet weld on a lap joint in steel plate welded with the gas metal
arc welding process in the 2F position.

Fillet and Groove Welding Combination Project: Job
Qualification Test 2 This combination test project will
allow you to demonstrate your ability to read a drawing,
develop a bill of materials (SI conversions are optional),
thermally cut, fit components together, tack, and weld
a carbon steel project. You will be using the techniques
developed in Jobs 22-J1 through J10 using the spray arc
mode of metal transfer. Follow the instructions found in
the notes on Fig.22-31 (p. 736).
Inspection and Testing After the project has been tacked,
have it inspected for compliance to the drawing. On mul-
tiple-pass welds, have your instructor inspect after each
weld unless otherwise instructed. Use the following ac-
ceptance criteria to judge your welds. Look for surface
defects. Keep in mind that it is important to have good
appearance and uniform weld contour. These character-
istics usually indicate that the weld was made properly
and that the weld metal is sound throughout. Only visual
inspection will be used on this test project to the following
acceptance requirements:
There shall be no cracks or incomplete fusion.
There shall be no incomplete joint penetration in
groove welds except as permitted for partial joint pen-
etration groove welds.
Your instructor shall examine the weld for acceptable
appearance and shall be satisfied that the welder is
skilled in using the process and procedure specified
for the test.
Undercut shall not exceed the lesser of 10 percent of
the base metal thickness or 132 inch.
Where visual examination is the only criterion for
acceptance, all weld passes are subject to visual
examination, at the discretion of your instructor.
The frequency of porosity shall not exceed one in each
4 inches of weld length, and the maximum diameter
shall not exceed 332 inch.

Gas Metal Arc Welding Practice with Solid and Metal Core Wire: Jobs 22-J1J23 (Plate) Chapter 22 733

Fig. 22-27 Fillet weld on a T-joint welded in the 2F position with the gas
metal arc welding process in steel plate.
Fig. 22-28 The first (root) pass of a V-groove butt joint welded in the 1G
position with the gas metal arc welding process in steel plate.
Fig. 22-29 Penetration through the back side of a V-groove butt joint welded
in the 1G position.
Welds shall be free from overlap.
Only minimal weld spatter shall be accepted, as
viewed prior to cleaning.
Groove Weld Project: Job Qualification Test 3 This test
project will allow you to demonstrate your ability to read
a drawing, fit components together, tack, and weld a car-
bon steel unlimited thickness test plate. You will be using
the techniques developed in Jobs 22-J1 through J10 using
the spray arc mode of metal transfer. Follow the instruc-
tions found in the notes on Fig.22-32, page 737.
Inspection and Testing After the project has been tacked,
have it inspected for compliance to the drawing. After the
project has been completely welded, use visual inspec-
tion and cut specimens for bend testing. Use the following
734 Chapter 22 Gas Metal Arc Welding Practice with Solid and Metal Core Wire: Jobs 22-J1J23 (Plate)
acceptance criteria to visually judge your welds.
Look for surface defects. Keep in mind that it is
important to have good appearance and uniform
weld contour. These characteristics usually in-
dicate that the weld was made properly and that
the weld metal is sound throughout. Once visual
inspection is completed to the following criteria,
you will perform side bend tests. Follow side
bend test procedures as outlined in Chapter 28.
There shall be no cracks or incomplete
fusion.
There shall be no incomplete joint penetra-
tion in groove welds except as permitted for
partial joint penetration groove welds.
Your instructor shall examine the weld for
acceptable appearance and shall be satisfied
that the welder is skilled in using the process
and procedure specified for the test.
Undercut shall not exceed the lesser of
10 percent of the base metal thickness or
1
32 inch.
Where visual examination is the only crite-
rion for acceptance, all weld passes are sub-
ject to visual examination, at the discretion
of your instructor.
The frequency of porosity shall not exceed
one in each 4 inches of weld length and the
maximum diameter shall not exceed 332 inch.
Welds shall be free from overlap.
Only minimal weld spatter shall be accepted,
as viewed prior to cleaning.
Side bend acceptance criteria as measured on
the convex surface of the bend specimen are the
following:
No single indication shall exceed 18 inch measured in
any direction on the surface.
The sum of the greatest dimensions of all indications
on the surface, which exceed 132 inch, but are less than
or equal to 18 inch, shall not exceed 38inch.
Cracks occurring at the corner of the specimens shall
not be considered unless there is definite evidence that
they result from inclusions, fusion, or other internal
discontinuities.
MIG Welding of Aluminum
You will recall that aluminum is readily joined by welding,
brazing, soldering, adhesive bonding, and mechanical fas-
tening. Aluminum is lightweight, and yet some of its alloys
have strengths comparable to mild steel. Pure aluminum
can be alloyed readily with many other metals to produce
 ( )
Inch Millimeters
See Notes 10 & 11
1/4 9/32 5/16
60 1/16 1.6
1/8 3.2
1/4 1/4 6.4
1/4 1/2 12.7
1/4 1 25.4
6"

11"
1D 6" 313/16" 1E See Note 8
3/4" TYP

2" 2"
2"

(5/16) 50
Manual OFC Manual
See
9/32
This Edge OFC- 1" 2"
Note 10 6"
1F
2"
1/2"
1C TYP
1B

( )
1 /4
1A 5" 2-4
8" 1/4 2-4 See Notes 10 & 12
9/32 5/16
50

Drawing Not to Scale

Part No. Reqd. Size S.I. Conversion
Tolerances:
1A Fractions: + or 1/16"
1B Angles: +10, 5

1C
1D
1E
1F

Notes:
1. All dimensions U.S. customary unless otherwise specified.
2. 3/8" thickness plain carbon steel material.
3. The welder shall prepare a bill of materials in U.S. customary units of measure prior to cutting.
4. The welder shall convert the above bill of materials to S.I. metric units of measure.
5. All parts may be mechanically cut or machine OFC unless indicated manual OFC.
6. All welds GMAW-S, FCAW-G, or FCAW-S as applicable.
7. Fit and tack entire assembly on bench before attaching to positioning fixture arm.
8. Attach 2" 2" extension tab of Part 1E to positioning fixture arm. All welding done in position according to drawing orientation.
9. Employ boxing technique where applicable.
10. Partial penetration weld.
11. Weld joins Part 1C and 1D to 1E.
12. Weld joins Part 1C and 1E to 1A.

Fig. 22-30 Performance Qualification Test GMAW-S. Adapted from AWS SENSE Program

Gas Metal Arc Welding Practice with Solid and Metal Core Wire: Jobs 22-J1J23 (Plate) Chapter 22 735
 (5/16) 60
See Note 10 Inch Millimeters
9/32
1/16 1.6
1/8 3.2
1/4 6.4
1/2 12.7
6" 1 25.4

Manual OFC
This Edge

Manual
OFC- 1" 2" 51/2"
1/4
1B
1/4
1/2" 2"

1A 1A
3" 11/2"
6"

Drawing Not to Scale

Part No. Reqd. Size S.I. Conversion Tolerances:
1A Fractions: + or 1/16"
1B Angles: +10, 5

Notes:
1. All dimensions U.S. customary unless otherwise specified.
2. 3/8" thickness plain carbon steel material.
3. The welder shall prepare a bill of materials in U.S. customary units of measure prior to cutting.
4. The welder shall convert the above bill of materials to S.I. metric units of measure.
5. All parts may be mechanically cut or machine OFC unless specified manual OFC.
6. All welds GMAW, spray transfer.
7. Fit and tack entire assembly on bench before welding.
8. All welding done in position according to drawing orientation.
9. Employ boxing technique where applicable.
10. Melt-through not required.

Fig. 22-31 Performance Qualification Test GMAW, Spray Transfer. Adapted from AWS SENSE Program

a wide range of physical and mechanical properties. It is
highly ductile and retains that ductility at subzero tempera-
tures. It has high resistance to corrosion, forms no colored
salts, and is not toxic. Aluminum has good electrical and
thermal conductivity and high reflectivity to both heat and
light. It is nonsparking and nonmagnetic.
Aluminum is easy to fabricate. It can be cast, rolled,
stamped, drawn, spun, stretched, and roll formed. The
metal may also be hammered, forged, and extruded into a
wide variety of shapes. Machining ease and speed are im-
portant factors in using aluminum parts. Aluminum may
also be given a wide variety of mechanical, electrochemi-
cal, chemical, and paint finishes.
Pure aluminum melts at 1,220F, and aluminum alloys
have an approximate melting range of 900 to 1,220F, de-
pending upon the alloying elements. Aluminum does not
change color when heated to the welding or brazing range.
This makes it difficult to judge when the metal is near the

736 Chapter 22 Gas Metal Arc Welding Practice with Solid and Metal Core Wire: Jobs 22-J1J23 (Plate)