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Metal Inert Gas Welding (GMAW)

MIG welding was developed in the 1940s to develop a suitable welding process for aluminum. It is now a semi-automatic process used for both non-ferrous and ferrous materials, from sheet metal fabrication to spacecraft manufacturing. MIG welding employs a constant voltage power supply and uses short circuiting, globular, or spray transfer methods. GTAW is an arc welding process that uses a non-consumable tungsten electrode and gas shielding to produce high quality, defect-free welds suitable for both ferrous and non-ferrous metals.

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51 views13 pages

Metal Inert Gas Welding (GMAW)

MIG welding was developed in the 1940s to develop a suitable welding process for aluminum. It is now a semi-automatic process used for both non-ferrous and ferrous materials, from sheet metal fabrication to spacecraft manufacturing. MIG welding employs a constant voltage power supply and uses short circuiting, globular, or spray transfer methods. GTAW is an arc welding process that uses a non-consumable tungsten electrode and gas shielding to produce high quality, defect-free welds suitable for both ferrous and non-ferrous metals.

Uploaded by

S Gouda
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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METAL INERT GAS WELDING

(GMAW)
METAL INERT GAS WELDING
(GMAW)
MIG welding
ldi iis one off th
the many versatile
til
process grouped in the heading “Gas Metal arc
welding process: (GMAW). MIG welding process
as d
was discovered
sco e ed in 1940’s
9 0 s to
o de
develop
e op a su
suitable
ab e
welding process for aluminium and also to
mechanise the same. MIG was introduced in
1948 primarily for welding of Aluminium, with the
rapid technological advances in the years that
followed the scope of the process developed
many other Non-ferrous and ferrous materials.
Today,y it is a well established semi-automatic
process which can be easily mechanised or
automated with wide range of application
spanning from simple sheet metal fabrication to
sophisticated space vehicle component
manufacture.
METAL INERT GAS WELDING
(GMAW):
‰GMAW employs constant voltage power
supply and uses either short circuiting,
globular or spray methods to transfer metal
from electrode to the work.
‰The type of transfer is determined by a
number of factors
¾Magnitude and type of welding current
¾Electrode diameter
¾Electrode composition
¾Electrode extension
¾Shielding gas
GMAW

Globular transfer
¾This process encompasses relatively low
current (below 250A) The globular transfer
mode is characterized by a drop size with a
diameter greater than that of the electrode.

¾In g
general,, this process
p is limited to the flat
position and can produce spatter
GMAW

Spray Transfer

¾The spray transfer mode results in a highly directed stream of


discrete drops that are accelerated by the arc forces.
p
¾Spatter is negligible
g g
¾Due to high arc force with high current, applying this process to
thin sheet may be difficult
¾The thickness limitation of spray arc process is overcome by use
of pulsed GMAW.
¾Pulsed GMAW is a variation of the GMAW in which the current is
pulsed to obtain the advantage of spray transfer at the less
average current than that if spray transfer mode
Advantages:
g ((GMAW))
1. The only consumable electrode process that can be used to
weld most commercial metals and alloys
2.
2 Good visibility
isibilit of weld
eld and heat affected zone
one d
during
ring welding.
elding
3. Continuous welding with coiled filler wires.
4. No slag removal and its associated difficulties like
interference with accurate jigging and clumsy work spot
spot.
5. High metal deposit rate
6. No welding fumes
7
7. High quality of weld
8. High welding speed
9. Less distortion
10
10. W ldi iin allll positions.
Welding iti
11. Because of the good heat input control this process is used
for non-ferrous welding with good results.
DISADVANTAGES: (GMAW)
1
1. When using the GMAW – S process, process the weld is more
susceptible to lack of adequate fusion.
2. Equipment for GMAW is sophisticated and therefore costly.
3
3. Constraint to use where
where, accessibility is limited as compared to
SMAW
4. Because of the higher spatter associated with GMAW the
p
deposition efficiency
y is less,, compared
p to TIG welding.
g
5. The absence of slag in solid wire welding process allows a
higher cooling rate of the weld zone. Joint made with this
process on hardenable steels are susceptible to weld metal
cracking.
ki
6. This process requires positive protection from strong drafts
which will reduce or eliminate the gas shielding from the arc
zone.
zone
7. Because of the instant arc, special filter glasses are required
to absorb gamma rays emanating from the arc.
8
8. Impure shielding can lead to high porosity in the weld
GAS TUNGSTEN ARC WELDING
(GTAW):
GAS TUNGSTEN ARC WELDING
(GTAW):
GAS TUNGSTEN ARC WELDING
(GTAW):
• GTAW is an arc welding process which
employs gas to protect the weld zone from
the atmosphere. Heat is supplied by an
intense electric arc, struck between a
virtually non-consumable Tungsten
electrode and the work piece.
• This process is used with shielding gas and
without application of pressure
pressure.
• Direct current welding is typically performed
with electrode negative (DCEN) polarity.
• DCEN Welding offers the advantage of
deeper penetration and faster welding
speeds.
GTAW
• AC provides a cathodic cleaning
(Sputtering) that removes refectory oxides
from the surfaces of the weld joint, which is
necessary for welding aluminum and
magnesium. The cleaning action occurs
during the portion of the ac wave, when the
electrode is positive with respect to the
work piece.
p
Advantages:
g GTAW
¾Produces high purity welds, generally free
from defects.
defects
¾Little post- weld cleaning is required
¾Allows excellent control of root pass weld
penetrations
t ti
¾Can be used with or without filler metal,
dependent on the application.
¾Due to its low heat input during welding,
generally these welds does not require
PWHT
Disadvantages:GTAW
g

¾Deposition rates are lo lower


er than the rates
possible with consumable electrode welding
process.
¾Has low tolerance for contaminations on
filler or base metals.
¾Difficult to shield the weld zone properly in
drafty environments
environments.

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