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Presentation on MIG-MAG Welding

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By N.K. Chawla
Mobile +91 9810191280

E-mail :nkchawla@kaizenmetal.com

Kaizen Metal Forming

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Welding as defined by American Welding Society Welding is defined as a joining process that produces coalescence (Fusion) of materials by heating them to the welding temperature, with or without the application of pressure or by the application of the pressure alone, and with or without the use of filler metal. In less technical language; A weld is made when separate pieces of material to be joined combine and form one piece when heated to a temperature high enough to cause softening or melting and flow together. Pressure may or may not be used to force the pieces together. Filler material is added when needed to form a completed weld in their joint.
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Welding is the most efficient way to join metals. Only way to join two or more pieces of metals to make them act as one piece. Welding is the most economical method to permanently join metal parts. All metals can be joined by one welding process or another. There is saying if it is metal, weld it and it is true. Look around, almost everything made of metal is welded, the worlds tallest building, moon rocket engines, nuclear reactors, home appliances and automobile, barely start the list. The use of welding is still increasing.
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Early metal joining methods

Welding Basics Weld joints - I

Welding Basics Weld joints - II

Welding Basics Welding positions

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GAS METAL ARC WELDNIG(GMAW) IS AN ARC WELDING PROCESS THAT USES AN ARC BETWEEN A CONTINOUS FILLER METAL ELECTRODE AND THE WELD POOL. IT WAS DEVELOPED IN THE LATE 1940S FOR WELDING ALUMINUM AND HAS BECOME VERY POPULAR . THERE ARE MANY VARIATIONS DEPENDING ON THE TYPE OF METAL TRANSFER,THE TYPE OF METAL WELDED, AND SO ON.IT HAS BEEN GIVEN MANY NAMES e.g-MIG WELDING,CO2 WELDING ,FINE WIRE WELDING ,SPRAY ARC WELDING, DIP TRANSFER WELDING , SHORT CIRCUIT ARC WELDING AND VARIOUS TRADE NAMES

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THE GAS METAL ARC WELDING PROCESS UTILIZE THE HEAT OF AN ARC BETWEEN A CONTINUOSLY FED CONSUMABLE ELECTRODE AND THE WORK TO BE WELDED. THE HEAT OF THE ARC MELTS THE SURFACE OF THE BASE METAL AND THE END OF THE ELECTRODE. THE METAL MELTED OFF THE ELECTRODE IS TRANSFERRED THROUGH ARC TO THE WORK WHERE IT BECOMES THE DEPOSITED WELD METAL.

SHIELDING IS OBTAINED FROM AN ENVOLOPE OF GAS,WHICH MAY BE INERT GAS . AN ACTIVE GAS, OR A MIXTURE.

THE ELECTRODE IS FED INTO THE ARC AUTOMATICALLY.

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The equipment required for a gas metal arc welding system consists of
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1-Power source. 2-Electrode wire feeder 3-Welding gun and cable assy. 4-Gas control system for shielding gas 5-Travel mechanism for automatic welding.

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Metals as thin as .13mm to 4.8mm can be welded without preparation. Metals from 1.6mm to 10mm can be welded in a single pass with joint preparation. Multipass welding is required above 10mm and preparation is needed. There is no limit to the thickness of metal that can be welded. GMAW electrode has a smaller diameter therefore the preparation for V-grooves may be made to a smaller angle. This saves as much as 50% on welding filler metal and weld time.

( NG )

(OK)

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Carbon dioxide is commonly used on mild steel for minimum cost. 25% carbon dioxide +75% argon is used for general welding of carbon steel, and low steel alloy steel with excellent result

The most common mixture are argon and CO2 in 75-25%, 80-20% and 85-15% mixture.
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CO2 is decomposed by high temperature of the arc . This endothermic reaction takes heat from the arc during dissociation, but where the temperature is lower , away from the arc and in contact with the work piece, the reaction is reversed (an exothermic reaction), giving to plate surface the heat borrowed from the center of the arc The complete reaction is written as:2CO2 = 2CO + O2 -136 calories The important point is the supplementary application of heat energy on work surface which has the effect of favoring penetration. This activity of CO2 is ,because of this , a very useful property and makes it favored gas for use in welding , it is called Metal Active Gas (MAG) welding
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The GMAW process includes distinctive metal transfer types:Short circuit transfer, globular transfer, normal spray transfer, pulsed spray transfer and rotational current high density transfer.
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Low currents allow the liquid metal at the electrode tip to be transferred by direct contact with the molten weld pool. This process requires close interaction between the wire feeder and the power supply. This technique is called short-circuiting transfer. If the system is properly tuned the rate of short-circuiting can reach hundred per second causing a characteristic buzzing sound. The spatter is low and process is easy to use in all position on sheet metal, low carbon steel, low alloy steel and stainless steel ranging in thickness from 0.5mm to2.6mm CO2 works well with the process. Pure argon is not affective . However, a mixture of 25% CO2 and 75% Argon produces a desirable well profile.
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Globular metal transfer occurs at an average current rate just above short circuit metal transfer. The electrode metal transfers in droplet 2 to 4 times the electrode dia. The droplets fall in irregular pattern with no set frequency. They fall under the influence of gravity and produce lot of turbulence in molten weld pool and also produce lot of spatters. Most often this type of transfer occurs when CO2 is the shielding gas. At low currents ,the drops are large and are transferred at rate below 10 per second.
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In an argon-rich shielding gas, the electrode metal transfer changes from globular to spray as welding current increases for any given electrode diameter . The change takes places at a value called the globular to spray transition current . Spray transfer in argon has constricted arc column and pointed electrode tip. Molten metal transfers across the arc as small droplets. The transfer rate can be as high several hundred droplets per second.
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Three conditions must be present for spray transfer to begin:Argon or Argon rich shielding gas must be used. DCEP polarity. Current level must be above the transition current when globular metal transfer changes to spray metal transfer.

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BEAD THICKNESS (a) mm

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FILET SIZE (b) mm

2.82

WEIGHT FOR DIFF EXCESS WELD METAL THICKNESS 0mm

31.4

0.5mm
41.6

1.0mm
52.6

2.5
3

3.53
4.24

49.5
70.6

62.8
86.4

75.4
102

3.5 4 4.5 5
5.5

4.95 5.65 6.36 7

7.77

96.5 126 160 196

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115 147 183 222

264

133 167 206 249

295

6
7

8.48
9.9

283
385

314
422

346
458

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10

11.21
14.14

502
785

544
838

586
889

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During the manual welding operation, the welder has control over certain factors that affect the weld quality. For example:-welder can increase or decrease the speed of travel, length of arc, angle of electrode etc. These variable can be divided into three classifications:-. 1)-Primary adjustable variable A) Travel speed B) Arc voltage C) Welding current

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2)-Secondary adjustment variable A) Stick out (tip to work distance) 3)-Pre selected variable A) Electrode or wire dia/size C) Welding current type B) Electrode or wire type D) Shielding gas composition B) Torch angle

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Due to these so many variable involved welding has been defined as Critical process in ISO 9000 standard 28

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The total radiated energy both visible and invisible of GMAW is much higher than SMAW processes, so extra precautions must be taken to protect the eyes and skin. Also because the GMAW process produces less smoke than the SMAW process, more of the radiation produced is available to harm the welder. To protect yourself, first, use the table to determine the filter glass shade to use on GMAW: try the darker shade for the current you are using, and drop to the next lighter shade until you can see the welding action clearly. Never drop to a shade lighter than the lowest recommended one.

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THANK YOU

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