ARC VOLTAGE (ARC LENGTH) IN GMAW

The terms arc voltage and arc length are often used interchangeably. It
should be noted. These terms have different connotations even though
they are directly related.

With GMAW, Arc Length is a critical variable that must be carefully controlled.

For example, in the spray-arc mode with argon shielding, an arc that
is too short experiences momentary short-circuits.
These short-circuits cause pressure fluctuations that pump air into the arc
stream, producing porosity or embrittlement due to absorbed nitrogen.

Too Long Arc Too Short Arc

 Tends to wander, affecting both the penetration
and surface bead profiles.  The electrode tip
 Can also disrupt the gas shield. In the case of short-circuits the
a buried arc with a carbon-dioxide shield, weld pool, causing
 A long arc results in an unburied condition and instability.
produces excessive spatter and porosity.

Arc voltage depends on the arc length as well as many other variables:
 The electrode composition and dimensions,
 The shielding gas, The welding technique,
 electrode extension, and even the length of the welding cable,

since arc voltage often is measured at the power source. As shown in

below figure.
Arc voltage is an approximate means of stating the physical arc length in
electrical terms even though the measured arc voltage also includes the
voltage drop in the electrode extension beyond the contact tip.

With all variables held constant, arc voltage is directly related to arc length.
Even though the arc length is the variable of interest and the variable that
should be controlled, the voltage is more easily monitored. Because of this
factor, as well as the requirement that the arc voltage be specified in the
welding procedure, the term arc voltage is commonly used.

Arc voltage settings vary depending on:

 the material, shielding gas, and transfer mode

Typical values are shown in below Table.

 Trial runs are necessary to adjust the arc voltage to produce the most
favourable arc characteristics and weld bead appearance.
 Trials are essential because the optimum arc voltage is dependent
upon a variety of factors, including
 metal thickness, the type of joint
 welding position, electrode size
 shielding gas composition, and the type of weld.

From any specific value of arc voltage, a voltage increase tends to flatten
the weld bead and increase the width of the fusion zone.
 Excessively high voltage may cause
 porosity, spatter, and undercut

A reduction in voltage results in a narrower weld bead with a higher crown

and deeper penetration.

Excessively low voltage may cause

 the “stubbing” of the electrode

A condition in which the electrode dips into the weld pool and then solidifies
into place due to the lack of a short-circuit current.

TRAVEL SPEED

The term Travel Speed is defined as the linear rate at which the arc is
moved along the weld joint. With all other conditions held constant,
weld penetration is maximum at an intermediate travel speed.

If Travel speed is If Travel speed is increased

decreased
The deposition of filler
metal per unit length
increases.
At very slow speeds:
the welding arc impinges
on the weld pool rather
than on the base metal,
thereby reducing the
effective penetration. A
wide weld bead is also a
result.
The thermal energy per unit length of weld
transmitted to the base metal from the arc is at
first increased because the arc acts more directly
on the base metal.
with further increases:
Less thermal energy per unit length of weld is
imparted to the base metal.
with further increases:
undercutting tends to occur along the toe of the
weld bead because insufficient filler metal has
been deposited to fill the path melted by the arc.

Therefore, the melting rate of the base metal first increases and then
decreases with increasing travel speed.

Source: Welding Hand Book - AWS