Beruflich Dokumente
Kultur Dokumente
(MIG Welding)
GMAW Unit Topics
2
Unit Objectives
• Upon successful – The AWS electrode
completion of the GMAW classification system
Unit of Study, you will – Taking the next step to
becoming a certified
have learned about: welder
– Properly protecting
yourself and others while
welding
– Setting up and operating
GMAW equipment
– Striking and maintaining
an arc
– Welding in four positions
using various electrodes
– Weld Inspection
3
GMAW Safety
4
GMAW Safety
• ‘GMAW Safety’ is supplemental
and does not replace the
information found in ‘Arc Welding
Basics’
• Understand and follow all safety
precautions listed in ‘Safety in
Welding, Cutting and Allied
Processes’ (ANSI Z49.1), and Arc
Welding Safety (E205)
• Understand and follow all warning
labels found:
– On welding equipment
– With all consumable packaging IfIfyou
youever
everhave
haveaaquestion
questionabout
aboutyour
your
– Within instruction manuals safety
safetyor
orthose
thosearound
aroundyou,
you,
• Read Material Safety Data Sheets PLEASE
PLEASEASK ASKYOUR
YOURINSTRUCTOR!
INSTRUCTOR!
(MSDS)
5
GMAW Safety
• Fumes and Gases can be dangerous
– Keep your head out of the fumes
– Use enough ventilation, exhaust at the arc, or both, to keep fumes and gases
from your breathing zone and the general area
– Local exhaust and mechanical ventilation can be used without reducing weld
quality
• Electric Shock can kill – to receive a shock your body must touch the electrode
and work or ground at the same time
– Do not touch the electrode or metal parts of the electrode holder with skin or wet clothing
– Keep dry insulation between your body and the metal being welded or ground
– The coil of wire is ‘electrically hot’ when the trigger is pulled
• Arc Rays can injure eyes and skin -Choose correct filter shade (See chart below)
6
GMAW Safety
7
GMAW Principles
8
GMAW Definition
• GMAW stands for Gas Metal
Arc Welding
• GMAW is commonly referred
to as MIG or Metal Inert Gas
welding
• During the GMAW process, a
solid metal wire is fed through
a welding gun and becomes
the filler material
• Instead of a flux, a shielding
gas is used to protect the
molten puddle from the
atmosphere which results in a
weld without slag
GMAW is the most widely used arc welding process in the
United States
9
GMAW Circuit
• Current flows from the power source through the gun cable,
gun, contact tip to the wire and across the arc. On the other
side of the arc, current flows through the base metal to the
work cable and back to the power source
– Shielding gas flows through the gun and out the nozzle
10
GMAW Components
Travel direction
Generally, drag on thin sheet
metal and push on thicker
materials
4 Shielding Gas
3
Weld Puddle
11
1 - Electrode
12
2 - Arc
13
3 - Weld Puddle
14
4 - Shielding Gas
• GMAW welding
requires a shielding
gas to protect the
weld puddle
• Shielding gas is
usually CO2, argon,
or a mixture of both
15
5 - Solidified Weld Metal
16
Application Activity
17
GMAW Components
Application Activity
• 2 __________
Travel direction
4 • 4 __________
• 5 __________
5 2 1
18
Equipment Set Up
19
GMAW Equipment Set Up
1. Connect work clamp
2. Select electrode
a. Type
b. Diameter
3. Select shielding gas
4. Turn power supply on
5. Adjust machine output
a. Wire feed speed
b. Voltage
6. Adjust gas flow rate
20
GMAW Process Variables
• Welding variables
– Wire Feed Speed (WFS)
– Voltage
• Operator controlled variables
– Travel speed
– Gun angles
– Contact tip to work distance
(CTWD)
– Gas flow rate
21
Striking an Arc
and Making a Weld
22
Striking an Arc
23
Laying a Bead
The
Theappearance
appearanceofofthe thepuddle
puddleandand
ridge where molten metal solidifies
ridge where molten metal solidifies
indicates
indicatescorrect
correcttravel
travelspeed.
speed.TheThe
ridge should be approximately
ridge should be approximately 3/8”3/8”
(10
(10mm)
mm)behind
behindthethewire
wireelectrode.
electrode.
Most
Mostbeginners
beginnerstend
tendtotoweld
weldtoo
toofast
fast
resulting in a ropey bead which
resulting in a ropey bead which
means
meansSLOW
SLOWdown!down!
24
Fill the Crater
25
Restarting a Bead
26
Modes of Metal
Transfer
27
Modes of Metal Transfer
• GMAW is a process that
features several distinctive,
individual methods and types
of metal transfer
• The mode of metal transfer is
determined by a number of
welding variables
– Voltage
– Amperage
– Shielding Gas
• By changing one or more
variables, you can go from
one metal transfer mode to
another
28
Modes of Metal Transfer
30
Axial Spray Arc Transfer
31
Troubleshooting
Welds
32
Troubleshooting Welds
• GOAL - Make Good Welds • Eliminate Ropey Convex bead
33
Advantages and
Limitations
34
Advantages of GMAW
35
Limitations of GMAW
36
AWS Classification of
GMAW Electrodes
37
AWS Classification of
GMAW Electrodes
ER70S-X
Electrode
Rod
70,000 psi Min. Tensile Strength
Solid
Chemistry, Amount of Deoxidizers (Silicon,
Manganese and/or Aluminum, Zirconium and
Titanium) X=2,3,4,6,7 or G
38
Lesson Plans
39
GMAW Lesson #1
• Objective: To run a stringer (straight) bead using short arc transfer and to fill the
crater
• Equipment:
– Single Process - Constant Voltage Power Source & Wire Feeder
Power MIG 215 or Power MIG 255C
– Multi-Process
Composite: Power MIG 350 MP
Combination: V-350/ LF-72 package
• Material:
– Mild Steel Plate – 3/16” or thicker
.035” SuperArc L-56 (ER70S-6)
100% CO2 or 25% CO2/ 75% Argon blend shielding gas
40
GMAW Lesson #2
• Objective: To make a fillet weld on a lap joint in the horizontal position (AWS
position 2F)
• Equipment:
– Single Process - Constant Voltage Power Source & Wire Feeder
Power MIG 215 or Power MIG 255C
– Multi-Process
Composite: Power MIG 350 MP
Combination: V-350/ LF-72 package
• Material
– Mild Steel Plate – 10 gauge
– .035” SuperArc L-56 (ER70S-6)
– 100% CO2 or 25% CO2/ 75% Argon blend shielding gas
2F
41
GMAW Lesson #3
• Objective: To make a fillet weld on a tee joint in the horizontal position
(AWS position 2F)
• Equipment:
– Single Process - Constant Voltage Power Source & Wire Feeder
Power MIG 215 or Power MIG 255C
– Multi-Process –
Composite: Power MIG 350 MP
Combination: V-350/ LF-72 package
• Material:
– Mild Steel Plate – 10 gauge
– .035” SuperArc L-56 (ER70S-6)
– 100% CO2 or 25% CO2/ 75% Argon blend shielding gas
2F
42
GMAW Lesson #4
• Objective: To make a fillet weld on a lap joint in the vertical position welding
down (AWS position 3FD)
• Equipment:
– Single Process - Constant Voltage Power Source & Wire Feeder
Power MIG 215 or Power MIG 255C
– Multi-Process –
Composite: Power MIG 350 MP
Combination: V-350/ LF-72 package
• Material:
– Mild Steel Plate – 10 gauge
– .035” SuperArc L-56 (ER70S-6)
– 100% CO2 or 25% CO2/ 75% Argon blend shielding gas
3FD
43
GMAW Lesson #5
• Objective: To make a fillet weld on a tee joint in the vertical position welding down (AWS
position 3FD)
• Equipment:
– Single Process - Constant Voltage Power Source & Wire Feeder
Power MIG 215 or Power MIG 255C
– Multi-Process –
Composite: Power MIG 350 MP
Combination: V-350/ LF-72 package
• Material:
– Mild Steel Plate – 10 gauge
– .035” SuperArc L-56 (ER70S-6)
– 100% CO2 or 25% CO2/ 75% Argon blend shielding gas
3FD
44
GMAW Lesson #6
• Objective: To make a butt weld with a gap in the vertical position
welding down
• Equipment:
– Single Process - Constant Voltage Power Source & Wire Feeder
Power MIG 215 or Power MIG 255C
– Multi-Process –
Composite: Power MIG 350 MP
Combination: V-350/ LF-72 package
• Material:
– Mild Steel Plate – 10 gauge
– .035” SuperArc L-56 (ER70S-6)
– 100% CO2 or 25% CO2/ 75% Argon blend shielding gas
3G
45
GMAW Lesson #7
• Objective: To make a fillet weld on a tee joint
in the overhead position (AWS position 4F)
• Equipment:
– Single Process - Constant Voltage Power
Source & Wire Feeder
Power MIG 215 or Power MIG 255C
– Multi-Process –
Composite: Power MIG 350 MP
Combination: V-350/ LF-72 package
• Material:
– Mild Steel Plate – 10 gauge
– .035” SuperArc L-56 (ER70S-6)
– 100% CO2 or 25% CO2/ 75% Argon blend
shielding gas
4F
46
GMAW Lesson #8
• Objective: To make a three pass fillet weld on a tee
joint in the horizontal position (AWS position 2F)
• Equipment:
– Single Process - Constant Voltage Power Source
& Wire Feeder
Power MIG 215 or Power MIG 255C
– Multi-Process –
Composite: Power MIG 350 MP
Combination: V-350/ LF-72 package
• Material:
– Mild Steel Plate – ¼”
– .035” SuperArc L-56 (ER70S-6)
– 100% CO2 or 25% CO2/ 75% Argon blend shielding gas
2F
47
GMAW Lesson #9
• Objective: To run a horizontal fillet weld on a tee joint using axial
spray transfer (AWS position 2F)
• Equipment:
– Single Process - Constant Voltage Power Source
& Wire Feeder
Power MIG 225C
– Multi-Process –
Composite: Power MIG 350 MP
Combination: V-350/ LF-72 package Material:
– Mild Steel Plate – ¼”
– .045” SuperArc L-56 (ER70S-6)
– 90% Argon/ 10% CO2 blend shielding gas
2F
48
AWS Connection
49
American Welding Society
(AWS) Connection
50
English, Math, and Science
Connection
51
National Academic Standards
Crosswalk
52