j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 2 ( 2 0 0 8 ) 391–397

journal homepage: www.elsevier.com/locate/jmatprotec

Short communication

Steps toward a new classification of metal transfer

in gas metal arc welding

Danut Iordachescu a,∗ , Luisa Quintino b

a Centro Láser-Universidad Politécnica de Madrid, Ctra.de Valencia, km. 7300, Campus Sur U.P.M., 28031 Madrid, Spain
b Instituto Superior Tecnico – STM, Ava Rovisco Pais, 1049-001 Lisboa, Portugal

a r t i c l e i n f o a b s t r a c t

Article history: This paper is reviewing the metal transfer according to the progress made in the weld-
Received 27 September 2006 ing sources and techniques development. It critically analysis the actual classification of
Received in revised form the metal transfer in GMA welding, describing the relevant phenomenon and proposing
13 August 2007 improvements, to make the understanding and the work easier in the field of arc welding.
Accepted 22 August 2007 Basic concepts are overviewed and defined or re-defined: fundamental transfer modes, nat-
ural vs. controlled transfer mode, variants vs. variances, mixed vs. combined modes, drop
spray transfer. The new classification is simpler, without loosing the logic of numbering,
Keywords: both from fundamental point of view (the physics of the transfer) and the technological one
Arc welding (the increasing of the values of the welding parameters). It is extremely important for all the
GMAW specialists involved in study, design or industrial applications of the arc welding technolo-
MIG gies to have know–how about the metal transfer and its implications on the process and
MAG weld parameters.
Metal transfer classification © 2007 Elsevier B.V. All rights reserved.

1. Introduction important for all the specialists involved in the study,

Robotised and automated welding requests closed loop con-
trol systems, including control units based on process models
(Iordachescu and Quintino, 2004; Quintino and Iordachescu,
2003). To create these models are both theoretically and prac-
tically important, increasing the awareness about the molten
metal transfer mode through the electric arc, as this influences
the weld results obtained.
Theoretically modelled during the last decades, with
remarkable practical implications (Wang et al., 2003;
Constantin et al., 2001), the metal transfer through the
arc helped to the integrated design of the various flexible
industrial systems (Dilthey et al., 2004). It is extremely
design or industrial applications of welding technologies
to have know–how about the metal transfer modes and its
implications on process parameters and weld characteristics.
A determinant contribution in this field is the IIW (Interna-
tional Institute of Welding) classification of the metal transfer
modes, which was achieved in SG212 and published by Prof.
Lancaster in 1984 (Lancaster, 1984). The first contribution to
this topic is dated 1976 (Anon., as referred by Lancaster, 1984)
and till today adjustments have been introduced as technology
develops and further understanding of this issue is being gath-
ered. It was unanimously welcome the initiatives of Norrish,
respectively, Ponomarev who had contributions to this topic
in IIW Annual Assembly in 2003 (Norrish, 2003; Ponomarev

∗
Corresponding author. Tel.: +34 626193415; fax: +34 91 336 55 34/331 69 06.
E-mail addresses: dan iord@yahoo.com, danut.iordachescu@upm.es (D. Iordachescu).
0924-0136/$ – see front matter © 2007 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2007.08.081
392 j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 2 ( 2 0 0 8 ) 391–397

Fig. 1 – Arc voltage–welding current diagrams illustrating transfer modes categories: (a) IIW classification (Ponomarev et al.,
2003); (b) simply natural transfer modes for a classical welding source (Andersen, 1990); (c) combined natural/controlled
simply diagram (Andersen, 2003) and (d) variant of simply transfer mode categories (Weman, 2003).

et al., 2003). In the last years, debates on this matter were
brought in the IIW Commission XII and SG 212 by Iordachescu
and Quintino (2004), respectively, by Iordachescu, Lucas and
Ponomarev.
Constant interest on the transfer mode has been shown by
the providers of welding sources (Fig. 1a–e). These are classi-
cal diagrams “transfer modes arc voltage and welding current”
and each equipment provider intends to offer a practical tool
to the user, to guide him for starting a job. Evolution of the
welding process and of the techniques of visualising the elec-
tric arc allowed a clearer understanding of the phenomenon,
leading to a more detailed description of it and underlining
the need of a new updated classification.
On the other hand, even when standardising (e.g., DIN
standards, Table 1), not too much coherence with the IIW clas-
sification of the transfer modes (Table 2 (Lancaster, 1984)) was
shown. It becomes clear the necessity of revising this clas-
sification, based on practical reasons and on improvements
and to propose a more comprehensive, useful and easy-to-use
variant.
Consequently, this paper is meeting the above-mentioned
needs, as well as reviewing the metal transfer according
to the progress made on the welding sources. Respond-
ing to the industry demand, the equipment producers
introduced innovation in arc welding technologies when
seeking, for example, lower heat input variants. Practi-
cally, new techniques were invented and these became
variances, more than variants, which make use of con-
trolled metal transfer modes, often in the transition
zones.
 j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 2 ( 2 0 0 8 ) 391–397 393

Table 1 – Classification of metal transfer in MIG/MAG, DIN 1010, part 4

Types of arc DIN symbol Droplet size Metal transfer

Dip-transfer arc k Fine Only in short-circuit, regular

Intermediate arc ü Fine to coarse Partly in short-circuit, partly short-circuit-free, irregular
Spray arc s Fine to superfine Short-circuit-free, regular
Globular-transfer arc I Coarse Irregular in short-circuit, partly short-circuit-free
Pulsed arc P Adjustable Short-circuit-free, regular

molten metal, even when using the controlled mode (Dilthey

Table 2 – IIW classification of metal transfer (Lancaster,
1984) and Ulrico, 2000).
Based on the previous amendments proposed in the
Designation of transfer Welding process (examples)
Commission XII and SG212, this paper proposes a revised clas-
type
sification of the metal transfer in GMA processes (welding,
1. Free flight transfer brazing). Thus, the concept of fundamental transfer modes is
1.1 Globular mainly proposed to feature the new classification (Table 3).
1.1.1 Drop Low-current GMA
Besides this, techniques to achieve these modes, as well
1.1.2 Repelled CO2 shielded GMA
as the related variants and variances may be additionally
1.2 Spray defined. This approach better fits the real transfer modes gen-
1.2.1 Projected Intermediate-current GMA
erated by the modern arc welding sources and processes and
1.2.2 Streaming Medium-current GMA
allows also classifying the transfer of the molten metal based
1.2.3 Rotating High-current GMA
on the physics of the process.
1.3 Explosive SMA (coated electrode)

2. Bridging transfer
2.1 Short-circuiting Short-arc GMA
2.2 Bridging without Welding with filler wire addition
interruptions
3. Slag protected transfer
3.1 Flux wall guided SAW
3.2 Other modes SMA, cored wire, electroslag
2. Types of metal transfer mode
Since the very beginning of arc welding, the main factors influ-
encing the metal transfer mode are the arc voltage and the
welding current. When increasing the values of both these
main technological parameters, the type of transfer is chang-
ing. This was observed when classical AC or DC welding
sources were used. The progress made by the welding sources
in the last decade radically changed the approach of the trans-
fer modes.
The well-known IIW classification (Quintino and
Iordachescu, 2003) is based on the concept of “natural”
transfer, which characterises the common welding sources.
Nowadays, we talk less about a natural transfer mode, since
different “controlled” transfer modes are preferred and used
in the major applications and in various processes. These
clear “variances” with respect to the “fundamental” transfer
modes must be featured, underscoring their place in such
classification.
On the other hand, even when using controlled transfer
modes, the solution chosen by the producer of the power
source usually varies, consequently influencing the transfer
mode. These may be “variants”, achieved by/or even different
techniques for getting a common goal and framing in the same
transfer mode category.
Of course, the welding processes have their particulari-
ties, which basically influence the type and variant of transfer
modes. Even when analysing a single process, factors like
shielding gases may drastically influence the transfer of the
3. Classifications of the fundamental metal
transfer modes in GMA processes
A metal transfer mode classification structured on the increase
of the current and voltage would be welcomed by most of the
people active in the field, as it would allow to clearly under-
stand the relation between the process parameters and metal
transfer modes, which are related with arc stability, bead
appearance and bead quality.
Based on the main type of forces playing the key-role on the
detachment of the molten metal from the wire electrode, three
main “categories” of fundamental transfer modes may be defined:
A. Short-circuiting—key-role played by the surface tension
resultant force.
B. Globular—key-role played by the gravity resultant force.
C. Spray—key-role played by the arc pressure resultant force.
To make the proposed classification simpler, only the level
two categories where denominated as fundamental transfer
modes, as shown in Table 3. This makes the classification
simpler, without loosing the logic of numbering, both from
fundamental point of view (the physics of the transfer) and
the technological one (the increasing of the values of the weld-
ing parameters). Consequently, the six fundamental transfer
modes in the new classification are: A-Short-circuiting, B1-
Globular drop, B2-Globular repelled, C1-Drop spray, C2-Streaming
and C3-Rotating.
The actual knowledge in the field of GMAW metal transfer,
as well as the opinions of the biggest majority of the spe-
cialists (e.g., those expressed during the debates in the IIW’s
Commission XII and SG 212) allows us to state that these five
categories cover both the natural and the controlled transfer
modes, as defined above (see Chapter 2) and also previously
(Iordachescu and Quintino, 2004; Norrish, 2003; Ponomarev et
al., 2003).
394 j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 2 ( 2 0 0 8 ) 391–397

Table 3 – Proposed classification of metal transfer in GMA processes

Proposed denomination Proposed name Sketch Comment Correspondent in IIW
(fundamental modes) (fundamental modes) classification (Lancaster,
1984)

2. Bridging transfer
A Short-circuiting

2.1 Short-circuiting

1. Free flight transfer

B1 Globular Drop

1.1 Globular
1.1.1 Drop

1. Free flight transfer

B2 Globular Repelled CO2 GMAW

1.1 Globular
1.1.2 Repelled

1. Free flight transfer

C1 Drop Spray (projected)

1.2 Spray
1.2.1 Projected or not
applicable, as presented by
Norrish (2003)

1. Free flight transfer

C2 Streaming

1.2 Spray
1.2.2 Streaming

1. Free flight transfer

C3 Rotating

1.2 Spray
1.2.3 Rotating

It may be considered that the drop spray is a fundamental
transfer mode if its denomination is extended also on the clas-
sically defined spray projected mode of transfer (Lancaster, 1984).
If this name is only used as it was defined by Norrish (2003), it
looses its relevance. The essential observation is that, in the
non-controlled (natural) processes, drop spray as defined by
Norrish (2003) is unstable, randomly occurring in a very nar-
row range of current (Quintino and Allum, 1984), namely the
transition current zone (see Fig. 2 and Chapter 4).
The experience shows that an association with sketches is
welcome when presenting a transfer mode classification. It is
also possible and useful that photos are to be used instead of
sketches.
More than this, several practitioners are suggesting associ-
ating diagrams as the ones presented in Fig. 1 with sketches,
pictures and/or videos. This may substantially increase the
whole level of understanding and knowledge on the metal
transfer mode in wider environments (students, researchers,
designers, industrial users, etc.), as well as the phenomeno-
logical approach of the GMA processes. Actually, an annex of
this classification is needed to detail the variants, variances,
mixed and combined modes, new techniques and special pro-
 j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 2 ( 2 0 0 8 ) 391–397
Fig. 2 – Natural transfer modes—U(I) diagram with the
existing IIW denominations.
cesses (cored wire GMAW, A-TIG with feeding metal, etc.). If
such an annex is a CD/DVD, it may contain fully illustrated
transfer processes (videos, photos) for all types of the transfer
modes.
Besides the fundamental modes, it was already noticed the
variances: mixed modes and combined modes (Ponomarev et
al., 2003). These variances are basically combining different
types of fundamental transfer modes. While the mixed modes
randomly involve two or more types of transfer modes, in
similar or dissimilar cycles, the combined transfer modes are
intentionally obtained by controlling the transfer through the
welding source (Ponomarev et al., 2003).
Variants of the fundamental transfer modes are achieved
by using special techniques. Since the equipment producers
are seeking for several years welding sources allowing lower
and much lower heat input, the main development in terms of
diversity was achieved in the short-circuiting transfer mode.
Thus, nowadays we can notice at least three important tech-
niques, leading to specific short-circuiting transfer:
- classic GMAW (controlled or not);
- STT (surface tension transfer);
- CMT (cold metal transfer).
When approaching the controlled transfer modes, it is also
important to firstly mention if we are dealing with:
- simply controlled process (open control, without feedback
loop);
- real-time controlled process (with feedback closed loop).
4. Basics of transfer modes in GMA
processes
The six fundamental transfer modes in GMAW, as illustrated
in Fig. 3, occur both when using what is usually called
“conventional” power supplies with no control over the cur-
rent/voltage pulse’s characteristics and when using a modern
controlled welding source. Nevertheless, it is possible to oper-
ate in controlled mode with the transfer modes occurring in
395
Fig. 3 – Fundamental transfer modes—U(I) diagram based
on the new classification.
forced conditions, possible to program using power supplies
where controlled pulse welding is available. The terminology
used in this paper to designate this second case is controlled
transfer modes, these being of two types: simply controlled and
real-time (closed-loop) controlled.
Short-circuiting transfer mode uses in a very short arc,
regularly interrupted by a bridge of molten metal (Table 3),
which obviously generates a short-circuit welding current. The
bridge, as well as detachment of the molten metal toward
the welding pool are governed mainly by the surface tension
resultant force, which is mainly well-balancing the other influ-
ences.
Globular drop transfers big drops of molten metal (bigger
than the diameter of the electrode wire), with a reduced fre-
quency (usually, there is just a single drop flying in a certain
moment). Increasing the welding current, the Globular repelled
transfer mode occurs, characterising the CO2 GMAW; this con-
sists in an upward repelled molten metal big “long” drop, as
shown also in the sketches of Table 3. In these last two modes
of transfer, the principal actor is the gravity resultant force,
which is responsible for well balancing and detachment of the
molten metal from the end of the electrode wire.
Drop spray was described by Norrish (2003) as “a unique
phenomenon which occurs in the region of the spray tran-
sition current. . .” (Fig. 2). The metal drop is defined as near
spherical, with a diameter slightly larger than the electrode
wire (20–40%), while the transfer is quite axial, producing low
fume. As proposed in the new classification, Drop spray can
also be extended to the spray projected process, in which the
metal drops are strongly projected against the welding pool,
are clearly successive and have a dimension comparable with
the diameter of the electrode wire (±50%). Consequently, this
denomination is now covering both the former drop spray and
spray projected transfer modes (Fig. 3).
With the increase of the current, when the drops become
smaller and more frequent, as a real “shower”, the transfer
becomes Streaming. Finally, at very high values of the welding
current, the molten metal is purely flowing, but the stream is
Rotating, due to the strong electromagnetic fields generated by
396 j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 2 ( 2 0 0 8 ) 391–397
the high values of the current. This description of the six funda-
mental transfer modes started from the lowest values of current
and voltage and went to the highest ones, the increasing of
the welding current playing an important role on the type of
the metal transfer (Table 3 and Fig. 3).
In case of the spray fundamental category, the main force
governing the transfer of the molten metal is the arc pres-
sure resultant, which assures the strong projection of the
metal toward the molten pool. When the current increases,
the same increased pressure is responsible for splitting the
molten metal in small drops and its strong projection toward
the molten pool, as well as for the generation and projection
of the rotating fluid metal stream.
The major areas regarding the fundamental transfer modes
are separated by the so-called transition current zones, char-
acterised by unstable processes. Firstly, revealed as shown
in Fig. 1a (Ponomarev et al., 2003), the transition area sep-
arating the globular and the spray fundamental group areas is
presented in Fig. 3 as the second transition current (Iordachescu
and Quintino, 2004). In such type of graphical representation,
the transfer mode “drop spray”, contributed in 2003 by Nor-
rish (Norrish, 2003), would be located overlapping the second
transient current area (Fig. 2).
It may be assumed that a transition current zone between
the short-circuiting and the globular areas, the first transi-
tion current also exists, as shown in Fig. 3 (Iordachescu and
Quintino, 2004). It must be also underlined the importance of
this first transition current zone. In the natural mode of transfer
(and the case of non-pulsed controlled when using welding
sources with inadequate dynamics (Ponomarev et al., 2003)),
the short-circuiting and globular drop mode randomly occur
inside this transition zone, generating what was defined as
mixed transfer modes (Ponomarev et al., 2003). Nevertheless,
such mixed transfer modes also occur in the second transition cur-
rent area, combining spray (mostly drop spray), globular (drop
or repelled) and/or even short-circuiting fundamental modes
of transfer. When controlled welding processes are used, pure
short-circuiting or drop spray may be obtained, as well as the
combined transfer modes (Ponomarev et al., 2003). To charac-
terise these transition areas where controlled transfer modes
occur, ellipses were used (Iordachescu and Quintino, 2004),
overlapping the fundamental transfer modes in the transient
current area, as shown in Fig. 1a (Ponomarev et al., 2003).
On the other hand, the fundamental and the controlled modes
can be presented together, in the same diagram as in Fig. 3,
which also illustrates the transfer modes presented in Table 3.
Thus, considering overlapping the natural and controlled
transfer areas for the fundamental transfer modes, it may be
noticed (Fig. 3) that the current and the voltage may present a
range of variation in the zones where controlled drop spray or
short-circuiting are achieved (Iordachescu et al., 2004). This vari-
ation may be due to the different ionisation voltages requested
by the shielding gases or to other technological reasons.
In case of processes addressing lowest heat input values,
the transfer may occur in globular drop or in short-circuiting
modes. Both these two modes occur around the first transient
current and precise control process is required to stabilize
them, supported by an appropriate welding source. Special
attention must be paid to the magnetic blow of the arc, since
the repelled mode may accidentally occur, even when work-
ing in controlled pulse and with inert or mixed shielding gases
(generating an undesired mixed transfer mode).
5. Conclusions
The present paper proposes to add to the recent contributions
on the transfer mode classification the following:
- identification of a first transition current zone, separating
the short-circuiting from the globular area; consequently and
according to the increasing current direction, the already
observed transition current zone separating the globular
from the spray area becomes the second transient current zone;
the question of the possible existence of other transition
zones arouse;
- a new metal transfer mode classification structured both on the
increase of the current and voltage and on the physics of the
transfer was proposed; it would allow to clearly understand
the relation between the process parameters and metal
transfer modes, which are related with arc stability, bead
appearance and bead quality;
- the six fundamental transfer modes denominated can be either
natural or controlled;
- basic concepts were explained and proposed to be systemat-
ically used in order to unify the description of the transfer
processes and their general common understanding: fun-
damental transfer modes, natural vs. controlled transfer mode,
variants vs. variances, mixed vs. combined modes, drop spray
transfer;
- the new classification is simpler and intuitive, fully accessible
and easy to use for all the specialists involved in welding;
- a new diagram “transfer modes vs. arc voltage and current inten-
sity” was proposed for the fundamental and controlled transfer
modes;
- based on these suggestions, a new table with the classi-
fication of the metal transfer modes in GMA (MIG-MAG)
processes is proposed.
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