5 Welding Processes

Part 2 of 3
5.4 GAS METAL ARC WELDING (GMAW)
GMAW is an arc welding process that uses an arc between continuous filler
metal electrode and the weld pool. The process is used with shielding from an
externally supplied gas and without the application of pressure. GMAW may
be operated in semiautomatic, machine, or automatic modes. It employs a
constant voltage (CV) power supply, and uses either the (1) short circuiting,
(2) globular, or (3) spray methods to transfer metal from the electrode to the
work: The type of transfer is determined by a number of factors. The most
influential are:
a. Magnitude and type of welding current.
b. Electrode diameter.
c. Electrode composition.
d. Electrode extension.
e. Shielding gas.
See Figures 5 and 6 for schematics of the GMAW equipment and welding
process.

CV
Gas metal arc welding
GMAW / MIG (metal
inert gas)

CV
Flux cored arc welding (FCAW)

CV
GMAW

http://www.docslide.com/gmaw-fundamentals/
GMAW

CV
GMAW

CV
Gas metal arc welding
GMAW / MIG (metal inert
gas)
5.4.1 Short Circuiting Transfer (GMAW-S)
GMAW-S encompasses the lowest range of welding currents and electrode
diameters associated with GMAW process. This process produces a fast
freezing weld pool that is generally suited for joining thin section, out-of
position, or root pass. Due to the fast-freezing nature of this process, there is
potential for lack of sidewall fusion when welding thickwall equipment or a
nozzle attachment.

CV
Short Circuit mode

http://www.ualberta.ca/~ccwj/videos/files/01_Fundamental%20GMAW%20Metal%20Transfer%20Modes/GMAW_Steel_8
5Ar-15CO2_Short-Circuit_001/GMAW_Steel_85Ar-15CO2_Short-Circuit_001.mp4
Short Circuit mode

http://www.ualberta.ca/~ccwj/videos/files/05_Tubular%20Wires/GMAW_Ni-WC_70Ar-30CO2_Short-
Circuit_001/GMAW_Ni-WC_70Ar-30CO2_Short-Circuit_001.mp4
Conceptual schematic of
metal transfers in GMAW:
(a) short circuit, (b)
globular, (c) pulse and (d)
spray
5.4.2 Globular Transfer
This process encompasses relatively low current (below 250 A). The globular
transfer mode is characterized by a drop size with a diameter greater than
that of the electrode. In general, this process is limited to the flat position and
can produce spatter.

CV
Globular transfer mode

http://www.ualberta.ca/~ccwj/videos/pages/Intro%20High%20Speed/
CV
Globular transfer mode

http://www.ualberta.ca/~ccwj/videos/pages/Intro%20High%20Speed/
http://www.ualberta.ca/~ccwj/videos/files/01_Fundamental%20GMAW%20Metal%20Transfer%20Modes/GMAW_Steel_8
5Ar-15CO2_Globular_001/GMAW_Steel_85Ar-15CO2_Globular_001.mp4
Globular transfer mode

http://www.ualberta.ca/~ccwj/videos/pages/Intro%20High%20Speed/
http://www.ualberta.ca/~ccwj/videos/files/05_Tubular%20Wires/GMAW_Ni-WC_85Ar-15O2_Globular_001/GMAW_Ni-
WC_85Ar-15O2_Globular_001.mp4
Globular transfer mode

http://www.weldsmith.co.uk/dropbox/cranu/110523_wavefor
ms_GMAW_steel/waveforms_GMAW_steel.html
Globular transfer mode

CV
5.4.3 Spray Transfer
The spray transfer mode results in a highly directed stream of discrete drops
that are accelerated by arc forces. Spatter is negligible. Due to its high arc
forces with high current, applying this process to thin sheets may be difficult.
The thickness limitation of the spray arc transfer has been overcome by the
use of pulsed GMAW. Pulsed GMAW is a variation of the GMAW in which the
current is pulsed to obtain the advantage of spray transfer at the less average
currents than that of spray transfer mode.

CV
Spray transfer mode

http://www.ualberta.ca/~ccwj/videos/files/01_Fundamental%20GMAW%20Metal%20Transfer%20Modes/GMAW_Steel_8
5Ar-15CO2_Spray_001/GMAW_Steel_85Ar-15CO2_Spray_001.mp4
5.4.4 Advantages of GMAW
Some commonly accepted advantages of the GMAW process include:
a. The only consumable electrode process that can be used to weld most
commercial metals and alloys.
b. Deposition rates are significantly higher than those obtained with SMAW.
c. Minimal post-weld cleaning is required due to the absence of a slag.

5.4.5 Limitations of GMAW

Limitations associated with GMAW are:
a. The welding equipment is more complex, more costly, and less portable
than that for SMAW.
b. The welding arc should be protected from air drafts that will disperse the
shielding gas.
c. When using the GMAW-S process, the weld is more susceptible to lack of
adequate fusion.

CV
Pulsed GMAW – Modified Spray Mode

CV
Pulsed GMAW – Modified Spray Mode

http://www.millerwelds.com/resources/articles/Pulsed-MIG-gmaw-aluminum/
CV
Pulse Spray transfer mode

http://www.ualberta.ca/~ccwj/videos/files/05_Tubular%20Wires/GMAW_Ni-WC_95Ar-5CO2_Pulsing_001/GMAW_Ni-
WC_95Ar-5CO2_Pulsing_001.mp4
GMAW-MIG

CV
GMAW-MIG

CV
GMAW-MIG

CV
GMAW-MIG

CV
GMAW-MIG

CV
GMAW-MIG

CV
GMAW- Automation
GMAW- Automation
GMAW- Automation
GMAW- Branch Pipe Welding
GMAW- Stainless Steel Piping
GMAW- Stainless Steel Piping