Gas Metal Arc Welding: An

Introduction
Gas Metal Arc Welding Defined:

 The Gas Metal Arc Welding Process is a

consumable welding process where an arc is
generated between a continuously fed, solid
wire electrode and the grounded base metal.
Heat from the arc melts the base metal and
the wire electrode allowing them to be joined
into a solid piece. The molten weld puddle is
protected from the atmosphere by an
externally supplied shielding gas.
GMAW Equipment Requirements:
 Constant voltage or potential power source
(DC only).
 Wire feed unit.
 Welding lead or MIG gun.
 Welding cables and ground clamp.
 Shielding gas equipment.
 Gas supply
 Regulator/Flow meter
 Gas hose
Advantages of the GMAW Process:

 High productivity (most productive of the

manual welding processes).
 Used to weld ferrous and non-ferrous metals.
 Continuously fed wire electrode (fewer stops
& starts).
 High deposition rates.
 Minimal post weld clean-up.
 Readily adaptable to automation.
Disadvantages of the GMAW
Process:
 High initial equipment cost.
 Welding equipment is more complex.
 Limited portability.
 Difficult to use in hard to reach places.
 Shielding gas susceptible to drafts.
 Lack of fusion with short circuit transfer (cold
lapping).
 Operator resistance to radiated heat and arc
intensity.
GMAW Applications:

 Production welding.
 Pipeline welding.
 Repair welding.
 Automotive/Motor sports welding.
 Automated applications.
GMAW Variables - Before Welding:
 Electrode selection, based on the type of metal
being welded.
 Shielding gas selection, based on the type of
electrode being used and the mode of metal transfer
being used.
 Voltage setting, based on the electrode size and
mode of metal transfer being used.
 Short circuit transfer
 Globular transfer
 Spray arc transfer
 Wire feed speed setting (WFS = Amperage).
GMAW Variables – During Welding:

 Electrode extension. Electrode extension is

the distance from the end of the contactor
tube to the end of the electrode. Correct
electrode extension is determined by the
electrode diameter and type. Correct
electrode extension for .035 steel wire is ¼ to
½ inch. Correct electrode extension is critical
for maintaining amperage and voltage
settings.
GMAW Variables – During Welding,
Continued:
 Gun angle. The GMAW process can be
performed using a leading or trailing gun
angle. Up to 20 degrees of gun angle can be
used for lead or trailing welding. A trailing or
drag angle will impart more heat into the
base metal. A lead or push angle will impart
less heat into the base metal. Both methods
are used extensively.
GMAW Variables – During Welding,
Continued:
 Travel speed. Finished welds created using
the GMAW process should be approximately
10 times the electrode diameter in width.
 Electrode motion. Electrode motion must be
used when using CO2 shielding gas. A half
circular, zigzag, back and forth or circular
motion can be used. When using argon
based shielding gas no gun motion is
necessary, but can be used.
Lack of Fusion or Cold Lapping:
 One of the major problems associated with the
GMAW process is the lack of fusion or cold lapping.
Lack of fusion can be caused by incorrect power
source set-up, operator error or both. To help
prevent lack of fusion, the welding operator should:
 Ensure that enough amperage is being used for the
diameter of the chosen electrode.
 Prove power source set-up and welding technique by
performing a “Clip Test”.
 Strive to keep the heat of the arc concentrated on the
leading edge of the weld puddle.