EVOLVED AROUND THE SAME TIME AS SAW

THE DRIVING FORCE WAS HIGHER PRODUCTIVITY

IN WELDING PROCESSES TILL THEN OXIDISED
METAL REMOVED BY SLAG - METAL REACTIONS.
IN GMAW THE OXIDATON OF METAL IS PREVENTED BY
INERT GAS COVER
THE PROCESS IS USED IN MANUAL / SEMI AUTOMATIC / FULLY AUTOMATIC MODES

SET - UP
THE MAIN CONSTITUENTS OF SET - UP
:
POWER SOURCE
WIRE FEEDER
GAS CYLINDER
CONTROL
MODULE
TORCH

WIRE IS FED FROM WIRE FEEDER

SHIELDING GAS FLOWS ALL ROUND THE WIRE
THE SHIELDING GAS PROTECTS :
THE
THE
THE
THE

HOT WIRE
MOLTEN DROPLETS DURING TRANSFER
MOLTEN POOL & SOLIDIFYING METAL
HOT PARENT MATERIAL

METAL TRANSFER
SHORT CIRCUITING TYPE
PROJECTED TYPE
GLOBULAR
STREAMING
SPRAY

INCREASING
CURRENT

SHORT CIRCUITING TRANSFER

HEAT INPUT IS LOWEST .

DROPLET FORMED GROW & SHORT WITH BASE METAL
DROPLET IS DETATCHED FROM WIRE
THIS MODE SUITABLE FOR WELDING THIN MATERIAL

THE PROJECTED TRANSFER

HIGH CURRENT
MULTIPLE FINE DROPLETS FORMED
PROJECTED WITH FORCE
THIS MODE SUITABLE FOR OUT OF POSITION WELDIN

PROCESS CONTROL
PROCESS IS STABILISED WHEN THE
WIRE FEED RATE = MELTING RATE
HENCE THERE IS ALWAYS A FEED BACK CONTROL
MANUAL ( SEMI AUTOMATIC ) OPERATION
USE POWER SOURCE WHICH HAS DROOPING I V RELATION .
USE VOLTAGE BASED FEED - BACK
SUITABLE FOR MANUAL OPERATION

AUTOMATIC

OPERATION

USE POWER SOURCE WITH CONSTANT VOLTAGE I - V

RELATION .
USE CURRENT BASED FEED - BACK
SUITABLE FOR AUTOMATIC WELDING

CONSUMABLES
GENERALLY 1.2 & 1.6 DIA WIRES ARE USED.
THE WIRES COME IN 12.5 Kg. SPOOLS
THE SPOOLS SHOULD BE SPIRALLY WOUND. ELSE
WIRE FEEDING PROBLEM CAN RESULT.

CONSUMABLES
MATERIAL

GMAW WIRE

CS

ER 70 S 6

LTCS

ER 70 S G

C 0.5 Mo

ER 70 S - A1

C 1.25 Cr 0.5 Mo

ER 80 S - B2

C 2.5 Cr 1 Mo

ER 90 S - B3

C 5 Cr 1 Mo

ER 80 S - B6

C 6-8 Cr 1 Mo

ER 80 S - B6

C 9 Cr 1 Mo

ER 80 S - B8

C 9 Cr 1 Mo Nb

--------------

Austenitic SS

ER3XX

GASES USED FOR SHIELDING :

A ; He ; A + He ; A + H2 ; A + CO2 (4 - 6 %) ;
A + CO2 ( 20 %) ; A + O2 ( 2 - 4 %).
GENERALLY USED A + 20 CO2 FOR CS &
LAS ;
PURITY
OF EXCEPT
LOCAL A
ARGON
GRADES
ALL ABOVE
+ 20 CO2
FOR: SS
COMMERCIAL 99.995 %
IOLAR III
99.993 %
IOLAR II
99.9978 %
IOLAR I
99.9986 %

PRAXAIR 99.995%
GUJ I
99.9993 %
GUJ II
99.9978 %
INOX I
99.9978 %

ADVANTAGES OF GMAW
CONTINUOUS PROCESS
DEPOSITION RATE ~ 5 - 6 Kg / Hr
EASILY AUTOMATED
CAN BE USED FOR WIDE VARIETY
OF MATERIALS
OUT OF POSITION WELDING POSSIBLE

DISADVANTAGES OF GMAW
EXPOSED ARC
TRAINED WELDER
NEEDED
VARIANTS OF GMAW
CO2 PROCESS AND FCAW PROCESS
ALSO KNOWN AS MAG PROCESS
SHIELDING GAS IS CO2
CO2 ----->
O
PROVIDES
SHIELDING

CO +
REACTS WITH Si & Mn
IN SOLID WIRE AND
WITH FLUX IN FLUX
CORED WIRES

CO2 ( SOLID WIRE )

STEEL.

USED FOR JOINING CARBON

CHEAP PROCESS

WELD TOUGHNESS IS NOT SO GOOD.

CO2

USED FOR SHIELDING

FAIRLY CHEAP PROCESS

GOOD WELD TOUGHNESS & OTHER MECH.
PROP.

FLUX CORED ARC WELDING

IS USED FOR WELDING

CARBON STEELS ,
SOME LOW ALLOY STEELS AND
STAINLESS STEELS

Trial 6

First Pass ( Root Run )

600 - 650

Wire Position at
Centre of
Groove

3 mm

2 mm

Second Pass

STUB SIDE

PIPE SIDE

Third Pass

Wire 3 mm from
Centre of Groove
towards stub end

STUB SIDE

PIPE SIDE

STUB SIDE

PIPE SIDE

CONSUMABLES
MATERIAL

FCAW WIRE

CS

E 70 T1

LTCS

E 80 TJ

C 0.5 Mo

E 70 T1-A1

C 1.25 Cr 0.5 Mo

E 80 T1-B2

C 2.5 Cr 1 Mo

E 90 T1-B3

C 5 Cr 1 Mo

E 80 T1-B6

C 6-8 Cr 1 Mo

E 80 T1-B6

C 9 Cr 1 Mo

E 80 T1-B8

C 9 Cr 1 Mo Nb

--------------

Austenitic SS

E3XX LT 1

SELF SHIELDED FCAW

FLUX CONTAINS ALUMINUM FOR KILLING WELD METAL
PROCESS USED FOR WELDING STATICALLY LOADED PARTS
FLUX IN THE WIRE PROVIDES SHIELDING
HENCE NO SHIELDING GAS IS USED

SYNERGIC MIG
SPECIAL POWER SOURCE -- GIVES PULSED CURRENT.
OVERALL HEAT INPUT IS MAINTAINED LOW.
WIRE MELTING TAKES PLACE IN EACH HIGH PULSE
TIME.
THE CURRENT, WIRE FEED & PULSING ARE
ADJUSTED AUTOMATICALLY.

INDIVIDU
ALEFFECT
S

SYNERGIC
EFFECTS

INITIAL PROCESS

IN PRODUCTION PROCESS

STARTING POINT

TOOLS USED :
-- Factorial Analysis
-- Taquchi Analysis

CURRENT
VOLTAGE
TORCH STANDOFF
SPEED OF ROTATION
TECHNIQUE
WORK ANGLE
LEAD / DRAG ANGLE
UPHILL / DOWNHILL WELDING

HIGH LOCALISED HEATING OCCURS

HEAT INPUT CONTROL CRUCIAL
CRATER PIPING TO BE ELIMINATED
CRATER FILLING IMPORTANT
GETTING GOOD BEAD PROFILE
CURRENT RAMP TO BE MANIPULATED
TORCH SETTING
WORK & LEAD / DRAG ANGLES
FOREHAND / BACKHAND WELDING
GOOD AESTHETIC APPEARANCE
TORCH SETTING
CURRENT SETTING
FOREHAND / BACKHAND WELDING

Distribution of Heat Unequal thickness are welded

Sufficient Overlap Too Less Incomplete Weld
Too Much Time Loss
Avoid lack of Penetration Proper Current & Voltage
Lack of side wall fusion Groove Weld - Angle ; Land ; Gap
Fillet Weld - Surface Contamination
Flange Rounding

HEAT INPUT REDUCTION

Mode

mm

A
amps

V
volts

S
mm/min

Auto

1.2

220 - 240

18 - 20

800

0.327

Manual

1.2

180 - 200

18 - 20

200

1.03

Auto

0.8

180 - 200

17 - 18

750

0.266

Manual

0.8

140 - 160

17 - 18

150

1.05

Wire Dia.

Heat Input

KJ/mm

ENSURE CABLE CONNECTION IS TIGHT

ENSURE NO LEAKAGE IN GAS PATH
NEVER BYPASS GAS SOLENOID
REGULARLY CLEAN LINER USE GOOD QUALITY LINERS
USE PROPER CONTACT TIP
DO NOT USE TOO HIGH CURRENT / VOLTAGE
REPLACE LEAKNG PRESSURE AND FLOW GAUGES

ESSENTIAL VARIABLES
MATERIAL WELDED
MATERIAL THICKNESS
SHIELDING GAS
GAS COMPOSITION
BACKING ?
BACKING TYPE
CONSUMABLE USED
CONSUMABLE TYPE
ADDITIONAL CONSUMABLE
ALLOY ADDITIONS
PREHEAT
POST WELD HEAT TREATMENT

METAL TRANSFER TYPE

TRAILING GAS ?
TRAILING GAS COMPOSITION

NONESSENTIAL VARIABLES
CURRENT TYPE
GROOVE TYPE

CURRENT VALUE

GROOVE ANGLE

POLARITY

ROOT GAP

PULSING PARAMETERS

ROOT FACE

VOLTAGE

WELDING POSITION

WELDING SPEED
WEAVING / STRINGER
SHIELDING CUP SIZE
SINGLE / MULTIPLE PASS
SINGLE / MULTIPLE ELECTRODE
PEENING / NO PEENING
MANUAL / AUTOMATIC