WELDING VARIABLES

&
THEIR EFFECTS

PROCESS VARIABLES

Welding amperage
Arc voltage
Travel speed
Electrode extension and stick out
Polarity
Electrode orientation
Weld joint position
Electrode diameter
Shielding gas and gas flow rate

EFFECT OF CURRENT ON BEAD SHAPE

EFFECT OF VOLTAGE ON BEAD SHAPE

EFFECT OF TRAVEL SPEED ON BEAD SHAPE

STICKOUT

Electrode stick-out and arc length in

DC-welding

3 - 5 mm
1 - 5 mm

Electrode stick-out depends on the current joint type used

EFFECT OF STICKOUT ON CURRENT

EFFECT OF STICKOUT ON WELD BEAD

POLARITY
Electrode Negative

Ions
+
+

Electrons

Electrode Positive

+
+

Ions
+

Electrons

Work Piece Positive

Work Piece Negative

Straight Polarity DCSP

Reverse Polarity DCRP

ELECTRODE ORIENTATION

Effect of the
Travel Angle
on the Weld
Bead Profile

EFFECT OF TORCH ANGLE ON BEAD SHAPE

TORCH POSITION

TORCH POSITION

BEAD CHARAACTERISTICS

TORCH MANIPULATION

TORCH MANIPULATION

TORCH MANIPULATION

TORCH MANIPULATION

SHIELDING GAS

Shielding gases are necessary for

gas metal arc welding to protect the
welding area from atmospheric
gases such as nitrogen and oxygen,
which can cause fusion defects,
porosity, and weld metal
embrittlement if they come in
contact with the electrode, the arc,
or the welding metal.

Shielding Gas

The choice of a shielding gas

depends on several factors, most
importantly:
the

type of material being welded and

the process variation being used

GMAW Process- Shielding Gas

Pure inert gases such as argon and

helium
are

only used for nonferrous welding;

with steel they cause
an erratic arc and encourage spatter
(Helium) or
do not provide adequate weld penetration
(argon)

Shielding Gas

Pure carbon dioxide, on the other hand,

allows for deep penetration welds but;
Encourages

oxide formation, which

adversely affects the mechanical properties
of the weld

Its low cost makes it an attractive

choice, but
the

arc is harsh, spatter is unavoidable,

making welding thin materials difficult

EFFECT OF SHIELDING GASES

Argon

Argon-Helium

Helium

CO2

Bead Contour & Penetration Patterns for

various Shielding Gases

Relative Effect of Oxygen versus Carbon Dioxide additions to

the shielding gas mixture

ARGON-OXYGEN

ARGON-CARBON DIOXIDE

CARBON DIOXIDE

Shielding Gas

Therefore, Ar & CO2 are mixed in a 75%/25%

or 80%/20% mixture, which reduces spatter
and makes it possible to weld thin steel
workpieces.
Ar is also commonly mixed with other gases,
such as oxygen, helium, hydrogen, and
nitrogen.
Addition of up to 5% oxygen encourages spray
transfer, which is critical for spray-arc and
pulsed spray-arc GMAW.
An argon-helium mixture is completely inert,
and is used on nonferrous materials.

GAS FLOW

The desirable rate of gas flow

depends primarily
on

weld geometry, speed, current, the

type of gas, and the metal transfer
mode being utilized

Welding flat surfaces requires

higher

flow than welding grooved

materials, since the gas is dispersed
more quickly.

Gas Flow

Faster welding speeds mean

that

more gas must be supplied to

provide adequate coverage.

Higher current requires

greater

flow, and generally, more

helium is required to provide adequate
coverage than argon.

Gas Flow
Metal Transfer Mode

Gas Flow required

Short circuiting & Pulsed 10 L/min (20 ft/h)

spray modes (small
weld pools)
Globular transfer

15 L/min (30 ft/h) is

preferred

Spray transfer (higher

heat input, larger weld
pool)

20-25 L/min (40

50 ft/h)

PLATE THICKNESS Vs GAS FLOW RATE

PLATE
THICKNESS

FOR BUTT JOINT IN

FLAT POSITION

FOR FILLET JOINT IN

FLAT POSITION

GAS FLOW RATE (LPM)

1.6--2mm

8--10

10

3mm

8--10

10

6mm

12

12

10mm

12

12

12mm

14

14

16mm

14

16

20mm

16

16

25mm

16

18

32mm

18

20

40mm

18

20

What currents for different sizes

electrodes.

(Amps)
Electrodes
Light
2.00mm
40
2.5mm
55
3.15mm
90
4.00mm
140
5.0 mm
180
6.3 mm
220

Welding current
Heavy
60
85
130
180
240
320

Medium
50
70
110
165
210
260

Relation Between Welding Variables

FOR BUTT WELDING IN FLAT POSITION
PLATE
THICKNESS

WIRE DIA
(mm)

WELDING CURRENT
(Amps)

ARC VOLTAGE
(Volts)

1.6--2mm

0.8

55-70

18

3mm

0.8

110-120

20-22

6mm

1.2

125

22

10mm

1.2

150

26

12mm

1.2

150-175

26

16mm

1.2

150-175

28

20mm

1.2

170-200

30

25mm

1.2-1.6

125-250

32

32mm

1.2-1.6

125-275

32

40mm

1.2-1.6

125-300

32

Adjustments in Welding Parameters & Techniques

THANKS