1

GMAW Principles



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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
3
GMAW Circuit
Three things happen
when the GMAW gun
trigger is pulled:
The wire electrode
begins to feed
The circuit becomes
electrically hot



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



4
GMAW Components
Lets look a little closer at the GMAW process
Travel direction
Electrode
1
Arc
2
Weld Puddle
3
Shielding Gas
4
5
Solidified Weld Metal
Generally, drag on thin sheet
metal and push on thicker
materials
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1 - Electrode
A GMAW electrode is:
A metal wire
Fed through the gun by
the wire feeder
Measured by its
diameter


GMAW electrodes are commonly
packaged on spools, reels and
coils ranging from 1lb to 1000lbs
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2 - Arc
An electric arc
occurs in the gas
filled space between
the electrode wire
and the work piece
Electric arcs can generate
temperatures up to 10,000F
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3 - Weld Puddle
As the wire electrode
and work piece heat
up and melt, they
form a pool of molten
material called a weld
puddle
This is what the
welder watches and
manipulates while
welding

.045 ER70S-6 at 400 ipm wire feed
speed and 28.5 Volts with a 90%
Argon/ 10% CO2 shielding gas
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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


The gauges on the regulator show
gas flow rate and bottle pressure
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5 - Solidified Weld Metal
The welder lays a
bead of molten metal
that quickly solidifies
into a weld
The resulting weld is
slag free
An aluminum weld done
with the GMAW process

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Troubleshooting
Welds



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Troubleshooting Welds
GOAL - Make Good Welds





Eliminate Porosity




Eliminate Ropey Convex bead





Eliminate Excessive Spatter

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AWS Classification of
GMAW Electrodes
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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
AWS Classification of
GMAW Electrodes