Gmaw Process

GMAW PROCESS
Presented by
Samrat Mazumdar
1
ESAB INDIA LIMITED, EQUIPMENT DIVISION, P-41, TARATALA ROAD, KOLKATA 700088, INDIA
Definitions
• MIG Metal Inert Gas

• MAG Metal Active Gas
• GMAW Gas Metal Arc Welding
2
CONTENTS
• Principle of Operation
• Process Variables & Parameters
• Metal Transfer
• Shielding Gases
• Power Source Characteristics
• Advantages & Limitations
• ESAB Product Range
3
Principle of Operation – GMAW
4
Process Variables – GMAW
VARIABLES DESCRIPTION
Welding Current Has a non-linear relationship with electrode feed speed or melting rate
Polarity DCEN – Direct Current Electrode Negative or Straight Polarity
(Straight / Reverse) DCEP – Direct Current Electrode Positive or Reverse Polarity
Arc Voltage An approximate means of starting the physical arc length
Travel Speed The linear arc rate at which the arc is moved along the weld joint
Stick Out The distance between the end of the electrode and the contact tube
Burn Back A time delay between wire feed unit starts to brake the wire until the
power unit shuts off the welding current
Higher electrode diameter requires higher current than comparatively
Electrode Diameter
smaller diameter electrodes and produce higher weld deposition
Shielding Gas Shields the molten metal from atmospheric contact
5
Welding Current & Wire Feed Speed
The welding current varies with the electrode feed speed or

melting rate in a melting rate in a non-linear relation. The
welding current is related to the wire feed speed by the
following mathematical formula.
WFS = a I + b LI2
WFS = the electrode feed speed, in/min (mm/s)
a = a constant of proportionality for anode or cathode
in/ (min. A) [mm/(S. A.)]
b = constant of proportionality for electric resistance
heating, min –1 A –2 (s –1 A –2)
L = the electrode extension or stick out, in (mm)
I = the welding current, A
6
Start Parameters – GMAW
Wire feed speed
(wfs) m/min
Hot start
Pre-set wire feed speed
Creep
start
Gas Time (sec)

pre flow
7
Stop Parameters – GMAW
Wire feed speed
(wfs) m/min
Pre-set wire feed speed
Crater fill
Burn back time
Gas post flow
Time (sec)
8
Hot Start
What is Hot Start?

Increased welding current for an
adjustable time at the start of welding
Without Hot Start
What are the advantages of Hot Start?

• Reduces the risk of poor fusion at the
start of the weld
• Complete penetration of the job
• Smooth start of plates
With Hot Start
• Avoid pre heating of the work piece
• Avoid 2 different parameter set ups
9
Crater Fill
What is the advantage of Crater Fill?

Without Crater Fill
Crater Filling helps to avoid pores,
thermal cracking and crater
formation in the work-piece at the
end of the weld.
With Crater Fill
10
Burn Back
What is the significance of Burn

Back time?
If the burn back time is too short it
leaves a long piece of filler wire
projecting after welding has stopped,
with resulting risk of the wire freezing Stick out
into the solidifying weld pool.
If the burn back time is too long it
reduces the stick out to such an extent
that there is a risk of the arc striking
from the welding gun contact tip when
welding is next started.
Time
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2 Stroke / 4 Stroke Operation in GMAW
Wire feeding
2-stroke
Time
Torch Switch
Wire feeding
4-stroke
Gas pre flow Gas post flow

Time
Torch Switch
12
Interval & Spot Welding – GMAW
Wire feeding
Spot
Welding
Time
Torch Switch
Wire feeding
Interval
Welding
Time
Torch Switch Pause time Welding time
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Metal Transfer – GMAW
• Short Circuit Transfer

• Globular Transfer
• Spray Transfer
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Short Circuit Transfer
15
Globular Transfer / Pulse Transfer
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Spray Transfer
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Pulsing in GMAW
Current
Why Pulsed Current?

• Less spatter – better weld quality
• Thicker wires for thinner material
• Reduction in welding smoke
Pulse current
Background
current
Time
Pulsetime Background time
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Shielding Gases used in GMAW
Shielding Gases provide a Types of shielding gases

shielding to the weld metal from used in GMAW are
the atmospheric contact and have
• Carbon Dioxide (CO2)
a pronounced effect on
• Argon
• Arc characteristics • Helium
• Mode of metal transfer • Oxygen
• Penetration and weld bead profile • Mixtures of above Gases
• Speed of welding
• Undercutting tendency
• Cleaning action
• Weld metal mechanical properties
19
Power Source Characteristics – GMAW
Constant Voltage Characteristics
VOLTAGE, V
CURRENT, A
The GMAW Power Source should have a Drooping Characteristics.
When welding is in progress the relation between the Welding Voltage (V) and
the Welding Current (I) is expressed by the following mathematical formula
V = 14 + 0.05 I
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Power Source Parameters – GMAW
PARAMETERS DESCRIPTION
Arc Voltage It is the electrical potential between the electrode and the work-piece
Slope Measured at two stable arc conditions of the CV characteristics
Inductance The inductance in the circuit controls the rate of current rise and in turn the
pinch effect.
SHORT
CIRCUIT
CURRENTS
SLOPE INDUCTANCE
21
GMAW Process –
Advantages & Limitations
Advantages of GMAW
• High Productivity
• Can weld all metals and alloys in all positions
• Long weld without stop and start
• Minimal post weld cleaning
Limitations of GMAW
• More complex
• Lacks portability
• Arc protection needed against air draft
22
Techno Commercial Advantages – GMAW
Basic Assumptions
1 MMAW Welding is done using MSGP electrode.
2 MIG is done using 1.6mm mig wire with CO2 as shielding gas.
3 MSGP Electrode has 93.5% efficiency.
4 MMAW is done with standard transformer & MIG is done using thyristorised machine.
5 2 shifts of working, each shift of 8 hours. Working time is 6 hours.
6 300 Working days per year.
7 Power cost @ Rs. 5.00/Unit.
8 Depreciation @ 10% - straightline method.
9 Interest rate @ 12% p.a.
10 CO2 gas flow rate @ 15l/min. Considering 10% wastage in purging & leakage @ 16.7l/min.
11 CO2 gas cost @ Rs.30.00/Kg.
12 Standard cost of Transformer Rs. 25,000/- & MIG machine Rs. 100,000/-.
13 Labour & Overhead cost @ Rs. 250.00 /man hr.
MIG wire 1.6mm dia. rate : Rs. 55/- per Kg. & Rate of MSGP Electrode as follows:
14
3.15 mm - Rs.1.50, 4.0 mm - Rs.2.50, 5.0 mm - Rs.4.00
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Final Cost Calculation
Welding Process MMAW MIG
CO2 Gas consumed, Kg 14.50

Gas Cost, Rs. 435.00
Electrodes consumed, Nos.
3.15mm 80
4.0mm 22
5.0mm 470
Electrode Cost, Rs. 2,055.00

MIG wire consumed, Kg. 32.14
MIG wire cost, Rs. 1,767.87
Welding Time, Minutes 1,428.12 440.64
Welding time, Days 1.98 0.61
Labour & Overhead Cost, Rs. 5,950.50 1,836.00
Power consumed, Units 84.55 71.79
Power Cost, Rs. 422.77 358.95
Interest Cost, Rs. 39.60 24.48
Depreciation Cost, Rs. 33.00 20.40
TOTAL COST, Rs. 8,500.87 4,442.70
Saving (% ) 47.74%
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ESAB GMAW Product Range
Diode based GMAW Thyristorised GMAW
• MIGMATIC 250 • AUTO K 400

• MIGMATIC 400 • AUTO K 600
• POWER COMPACT 255
Inverter based GMAW
• ESABMIG 300i / C300i

• ARISTOMIG 300 / C300
• ARISTOMIG 400 / U400
• ARISTOMIG 500 / U500
31
Thank You
32

Gmaw Process - 140306 - Ver 2.0

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• MIG Metal Inert Gas

The welding current varies with the electrode feed speed or

Gas Time (sec)

Pre-set wire feed speed

Burn back time

Gas post flow

What is Hot Start?

What are the advantages of Hot Start?

What is the advantage of Crater Fill?

What is the significance of Burn

Gas pre flow Gas post flow

Torch Switch Pause time Welding time

• Short Circuit Transfer

Why Pulsed Current?

Pulsetime Background time

Shielding Gases provide a Types of shielding gases

CO2 Gas consumed, Kg 14.50

Electrode Cost, Rs. 2,055.00

Diode based GMAW Thyristorised GMAW

• MIGMATIC 250 • AUTO K 400

Inverter based GMAW

• ESABMIG 300i / C300i

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