Gas Metal Arc Welding Metal Inert Gas Metal Active Gas

CSWIP 3.
1 Welding Inspection
Gas Metal Arc Welding

Metal Inert Gas
Metal Active Gas
Copyright © TWI Ltd 2008

TWI Training & Examination Services
Course Reference WIS 5
Course notes section reference 13
The MIG/MAG welding process was initially developed in the

USA in the late 1940s for the welding of aluminum alloys.
The latest EN Welding Standards now refer the process by the
American term GMAW (Gas Metal Arc Welding)
• The process uses a continuously fed wire electrode
• The weld pool is protected by a separately supplied
shielding gas

• The process is classified as a semi-automatic welding
process but may be fully automated
• The wire electrode can be either bare/solid wire or flux
cored hollow wire
MIG/MAG - Principle of operation

PROCESS CHARACTERISTICS
• Requires a constant voltage power source, gas supply, wire
feeder, welding torch/gun and ‘hose package’
• Wire is fed continuously through the conduit and is burnt-off
at a rate that maintains a constant arc length/arc voltage
• Wire feed speed is directly related to burn-off rate
• Wire burn-off rate is directly related to current

• When the welder holds the welding gun the process is said
to be a semi-automatic process
• The process can be mechanised and also automated
• In Europe the process is usually called MIG or MAG
Equipment for MIG/MAG
External wire Transformer/

feed unit Rectifier
Internal wire
feed system Power cable &
hose
assembly
Power control
panel

Liner for wire
15kg wire spool
Welding gun
Power return assembly
cable
MIG/MAG wire drive system
Internal wire
drive system Plain top roller

Half grooved
bottom roller Wire guide
Types of wire drive systems:

2 roll wire drive 4 roll wire drive
Types of drive rolls
•recommended for steel

wires

•recommended for softer
wires (aluminium)

Close wound Teflon
stainless liner
steel spring
wire liner
MIG/MAG welding gun types
Goose neck type

Push-pull type
MIG/MAG welding gun assembly
Welding gun assembly Welding gun body
(less nozzle)
On/Off switch
Spatter
protection
Hose
port

Nozzles or Spot welding
shrouds spacer
Gas diffuser Contact tips

MIG/MAG welding gun assembly
The Push-Pull gun
Contact Gas
tip diffuser
Union nut
WFS remote

control
Trigger
potentiometer
Gas
nozzle
ARC CHARACTERISTICS
Constant Voltage Characteristic
OCV Small change in voltage =

large change in amperage
Large arc gap
Small arc gap
The self

Volts adjusting arc.
Amps
MAG Welding Variable Parameters
Wire feed speed:

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

Current:
The current is automatically increased as the wire feed is
increased. Current mainly affects penetration
Inductance:
• Applicable to MIG/MAG process in dip transfer mode.
• The electrode is fed slowly through the arc until it touches the
weld pool, at this point the output from the power supply is
short circuited and a very high current flows through the
electrode. If this was allowed to continue, the wire would melt
and eject excessive amounts of spatter.

• The inclusion or the choke in the welding circuit controls the
rate at which the current rises so that the electrode tip is
melted uniformly without excessive spatter
Shielding Gases:
The gasses used in MIG/MAG welding can be either 100% CO2
or Argon + CO2 mixes.
• 100% CO2: Can not sustain true spray transfer, but gives
very good penetration. The arc is unstable which produces
a lot of spatter and a coarse weld profile.
• Argon + CO2 mixes: Argon can sustain spray transfer above

24 volts, and gives a very stable arc with a reduction in
spatter. Argon being a cooler gas produces less penetration
than CO2. Argon in normally mixed with CO2 at a mixture of
between 5-25%
MODES OF METAL TRANSFER

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

•pulsed transfer
Dip Transfer: (Voltage < 22) / (Amperage < 200)

• Thin materials positional welding
Globular Transfer: Between Dip & Spray Transfer
• Limited commercial, Used only in some mechanised MAG
process using CO2 shielding gas
Spray Transfer: (Voltage > 27) / (Amperage > 220)
• Thicker materials, limited to flat welding positions, high deposition

Pulse Transfer: Both spray and dip transfer in
• one mode of operation, frequency range 50-300 pulses/second
• Positional welding and root runs
MIG/MAG - metal transfer modes
Electrode diameter = 1,2
Voltage mm
WFS = 8,3 m/min
Current = 295 A
Voltage = 28V
Globular Spray transfer
transfer
Electrode diameter = 1,2 mm
WFS = 3,2 m/min

Current = 145 A
Voltage = 18-20V
Dip transfer
Current
Current/voltage conditions
MIG/MAG-methods of metal transfer
Dip transfer
• Transfer occur due to short circuits
between wire and weld pool, high level
of spatter, need inductance control to
limit current rise
• Can use pure CO2 or Ar- CO2 mixtures
as shielding gas
• Metal transfer occur when arc is
extinguished

• Requires low welding current/arc
voltage, a low heat input process.
Resulting in low residual stress and
distortion
• Used for thin materials and all position
welds
The pinch effect
Current 2
Pinch force P 
CSA

Globular transfer
• Transfer occur due to gravity or
short circuits between drops and
weld pool
• Requires CO2 shielding gas
• Metal transfer occur in large drops
(diameter larger than that of
electrode) hence severe spatter
• Requires high welding current/arc

voltage, a high heat input process.
Resulting in high residual stress
and distortion
• Non desired mode of transfer!
Spray transfer
• Transfer occur due to pinch effect
NO contact between wire and weld
pool!
• Requires argon-rich shielding gas
• Metal transfer occur in small
droplets, a large volume weld pool
•

Requires high welding current/arc
voltage, a high heat input process.
Resulting in high residual stress and
distortion
• Used for thick materials and
flat/horizontal position welds
Pulsed transfer
• Controlled metal transfer  one
droplet per pulse  NO transfer during
background current!
• Requires special power sources
• Metal transfer occur in small droplets
(diameter equal to that of electrode)

• Requires moderate welding current/arc voltage 
reduced heat input  smaller residual stress and
distortions compared to spray transfer
• Pulse frequency controls the volume of weld pool  used
for root runs and out of position welds
Pulse current parameters
Current (A)
Peak
current Average current
Transition (ammeter reading)
current

Background
current
Time (sec)
Pulsed Transfer
Current Ip = peak current (spray transfer)

Ib = background current (continuous arc but little or no fusion)
Ip

Ib
Tp Tb
Tp = peak time Time
Tb = background time
Contact tip Electrode

Contact tip recessed extension
extension Electrode
(3-5 mm) 19-25 mm
(0-3,2 mm) extension
6-13 mm

Set-up for dip transfer Set-up for spray transfer
The effect of inductance
Controls the rate of current rise
Current (A)
Short circuit Excessive current, high
current spatter
No inductance

Desired current for
good stability, low
spatter
Time (sec)
The effect of inductance
Maximum inductance Minimum inductance
•reduced spatter
•Colder arc  used only for
•Hotter arc  more arc stability when welding
penetration wide gaps
•More fluid weld pool  •Convex weld, more spatter
flatter and smoother weld
•Improved weld pool control
•Recommended on thicker
•Recommended on thin
materials and stainless
materials
steels

MIG/MAG process variables
• Welding current
•Increasing welding current

•Increase in depth and width
•Increase in deposition rate
• Polarity

MIG/MAG process variables
Electrode
orientation
Penetration Deep Moderate Shallow

Excess weld metal Maximum Moderate Minimum
Undercut Severe Moderate Minimum
• Electrode
extension
•Increased extension
Types of Shielding Gas

MIG (Metal Inert Gas)
• Inert Gas is required for all non-ferrous alloys (Al, Cu, Ni)
• Most common inert gas is Argon
• Argon + Helium used to give a ‘hotter’ arc - better for thicker

joints and alloys with higher thermal conductivity
Types of Shielding Gas

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

Ar + 20% CO2 for C-Mn & low alloy steels
Ar + 2% O2 for stainless steels
100% CO2 can be used for C - steels
MIG/MAG – shielding gases
Type of material Shielding gas
Carbon steel CO2 , Ar+(5-20)%CO2
Stainless steel Ar+2%O2

Aluminium Ar
Pulsed Transfer
Transfer-mode advantages
• Good fusion
• Small weld pool allows all-position welding
Transfer-mode disadvantages

• More complex & expensive power source
• Difficult to set parameters - requires power source
manufacturer to provide pulse programmes to suit wire type,
dia. and type of gas
Types of Filler Wire

• Filler wires have similar composition to the base material
• Wires can be solid, flux cored or metal cored
• Flux cored wires are designed to run in spray mode and therefore
they give good fusion
• Flux cored wires cannot be used for root runs on unbacked joints
• The slag formed from flux cored wire enables welding to be done in
all-positions
• Most flux cored wires have a folded seam that can allow moisture to

get into the flux
• Controlled storage & handling is required for ‘seamed’ wires
• Metal cored wires have the same general characteristics as solid
wires - they can be operated in dip or spray mode
• Some flux cored wires do not require a gas shield (Innershield)
Checks when GMAW welding
The welding equipment
A visual check should be made on the equipment to
ensure it is in good working order
The electrodes
The diameter, specification and the quality of the wire
are essential for inspection. The level of deoxidisation in

the wire, single, double or triple de-oxidised. The quality
of the wire winding and the copper coating should also
be inspected to minimize wire feed problems.
Checks when MAG welding
Wire liner
Check that the liner is the correct type and size for the wire
being used. Steel liners for steel and Teflon liners for
aluminium.
Contact tips
Check the tip is the correct size for the wire being used and
check the amount of wear. Excessive wear will affect wire
speed and electrical current pick-up

Gas and gas flow-rates
Type of gas and the flow rate need to be checked to ensure
they comply with the WPS
Other welding variables
Check WFS, amps, volts and travel speed
MIG/MAG typical defects
Most welding imperfections in MIG/MAG are caused by lack of
welder skill, or incorrect settings of the equipment
•Worn contact tips will cause poor power pick up, or transfer
•Bad power connections will cause a loss of voltage in the arc
•Silica inclusions (in Fe steels) due to poor inter-run cleaning
•Lack of fusion (primarily with dip transfer)
•Porosity (from loss of gas shield on site etc)

•Solidification problems (cracking, centerline pipes, crater
pipes) especially on deep narrow welds
MIG/MAG Arc Welding
Advantages Disadvantages
 High productivity  Lack of fusion (dip)
 Easily automated  Small range of consumables
 All positional (dip & pulse)  Protection on site
 Material thickness  Complex equipment
range  Not so portable

 Continuous electrode
Questions
Metal Active Gas Welding
QU 1. State the possible problems when using the dip transfer
mode in the MAG welding process
QU 2. State the application areas for the spray transfer mode

when using the MAG welding process.
QU 3. What power source characteristic is required and electrode

polarity/current type for the MAG welding process

QU 4. State the main variables for the MAG welding process
QU 5. State the advantages and disadvantages of the MAG welding

process when compared to MMA
Flux Core Arc Welding

Flux cored arc welding
FCAW
methods

With gas Without gas With metal
shielding - shielding - powder -
“Outershield” “Innershield” “Metal core”
“Outershield” - principle of operation

“Innershield” - principle of operation

ARC CHARACTERISTICS
Constant Voltage Characteristic
OCV Small change in voltage =

large change in amperage
Large arc gap
Small arc gap
The self

Volts adjusting arc.
Amps
FCAW - differences from MIG/MAG
• usually operates in DCEP

but some “Innershield”
wires operates in DCEN
• power sources need to
be more powerful due to
the higher currents
• doesn't work in dip
transfer mode

• require knurled feed rolls
• “Innershield” wires use

a different type of
welding gun
350 Amps self shielded welding gun
Close wound stainless 24V insulated

Handle
steel spring wire liner switch lead
(inside welding gun cable)
Conductor
tube
Welding
Trigger
gun cable

Thread protector
Hand shield
Contact tip
Courtesy of Lincoln Electric

Self shielded electrode

nozzle

75°
90°
Travel Angle
75°

Backhand (“drag”) technique
Advantages
• preferred method for flat or horizontal position
• slower progression of the weld
• deeper penetration
• weld stays hot longer  easy to remove dissolved
gasses

Disadvantages
• produce a higher weld profile
• difficult to follow the weld joint
• can lead to burn-through on thin sheet plates
Forehand (“push”) technique
Advantages
• preferred method for vertical up or overhead
position
• arc is directed towards the unwelded joint 
preheat effect
• easy to follow the weld joint and control the
penetration

Disadvantages
• produce a low weld profile, with coarser ripples
• fast weld progression  shallower depth of
penetration
• the amount of spatter can increase
FCAW advantages
• less sensitive to lack of fusion

• requires smaller included angle compared to MMA
• high productivity
• all positional
• smooth bead surface, less danger of undercut
• basic types produce excellent toughness properties
• good control of the weld pool in positional welding

especially with rutile wires
• seamless wires have no torsional strain  twist free
• ease of varying the alloying constituents
• no need for shielding gas
FCAW advantages
Deposition rate for carbon steel welding

FCAW disadvantages
• limited to steels and Ni-base alloys

• slag covering must be removed
• FCAW wire is more expensive on a weight basis
than solid wires (exception: some high alloy steels)
• for gas shielded process, the gaseous shield may be
affected by winds and drafts
• more smoke and fumes are generated compared

with MIG/MAG
• in case of Innershield wires, it might be necessary to
break the wire for restart (due to the high amount of
insulating slag formed at the tip of the wire)
FCAW advantages/disadvantages
Advantages: Disadvantages:
1) Field or shop use 1) High skill factor
2) High productivity 2) Slag inclusions
3) All positional 3) Cored wire is Expensive

4) Slag supports and shapes 4) High level of fume
the weld Bead (SSFCAW)
5) No need for shielding gas 5) Limited to steels and
nickel alloys
Any Questions

Gas Metal Arc Welding Metal Inert Gas Metal Active Gas

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CSWIP 3.

Gas Metal Arc Welding

Copyright © TWI Ltd 2008

The MIG/MAG welding process was initially developed in the

Copyright © TWI Ltd 2008

Copyright © TWI Ltd 2008

Copyright © TWI Ltd 2008

External wire Transformer/

Copyright © TWI Ltd 2008

Copyright © TWI Ltd 2008

Types of wire drive systems:

Copyright © TWI Ltd 2008

Types of drive rolls

•recommended for steel

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Copyright © TWI Ltd 2008

Goose neck type

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Copyright © TWI Ltd 2008

Gas diffuser Contact tips

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Constant Voltage Characteristic

OCV Small change in voltage =

Small arc gap

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Wire feed speed:

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MODES OF METAL TRANSFER

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Dip Transfer: (Voltage < 22) / (Amperage < 200)

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The pinch effect

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Current Ip = peak current (spray transfer)

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Tp = peak time Time

Contact tip Electrode

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•Increasing welding current

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Penetration Deep Moderate Shallow

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Undercut Severe Moderate Minimum

Types of Shielding Gas

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Types of Shielding Gas

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Type of material Shielding gas

Carbon steel CO2 , Ar+(5-20)%CO2

Stainless steel Ar+2%O2

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Types of Filler Wire