1 The Process

Known in the USA as gas metal arc welding (GMAW). The MIG/MAG
welding process is a versatile technique suitable for both thin sheet and
thick section components in most metallic materials. In the process, an arc
is struck between the end of a wire electrode and the workpiece, melting
both to form a weld pool. The wire serves as the source of heat (via the arc
at the wire tip) and filler metal for the joint. The wire is fed through a copper
contact tube (also called a contact tip) which conducts welding current into
the wire. The weld pool is protected from the surrounding atmosphere by a
shielding gas fed through a nozzle surrounding the wire. Shielding gas
selection depends on the material being welded and the application. The
wire is fed from a reel by a motor drive, and the welder or machine moves
the welding gun or torch along the joint line. The process offers high
productivity and is economical because the consumable wire is continuously
fed. A diagram of the process is shown in Figure 1.

The MIG/MAG process uses semiautomatic, mechanised, or automatic

equipment. In semiautomatic welding, the wire feed rate and arc length are
controlled automatically, but the travel speed and wire position are under
manual control. In mechanised welding, all parameters are under automatic
control, but they can be varied manually during welding, eg steering of the
welding head and adjustment of wire feed speed and arc voltage. With
automatic equipment, there is no manual intervention during welding.
Figure 1.1 shows equipment required for the MIG/MAG process.

Figure 1 MIG/MAG welding.

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 Figure 1.1 MIG/MAG welding equipment.

Advantages of the MIG/MAG process:

• Continuous wire feed

• Automatic self-regulation of the arc length
• High deposition rate and minimal number of stop/start locations
• High consumable efficiency
• Heat inputs in the range 0.1-2.0kJ/mm
• Low hydrogen potential process
• Welder has good visibility of weld pool and joint line
• Little or no post weld cleaning
• Can be used in all positions (dip transfer)
• Good process control possibilities
• Wide range of application

1.1.1 Disadvantages
• No independent control of filler addition
• Difficult to set up optimum parameters to minimise spatter levels
• Risk of lack of fusion when using dip transfer on thicker weldments
• High level of equipment maintenance
• Lower heat input can lead to high hardness values
• Higher equipment cost than MMA (manual metal arc) welding
• Site welding requires special precautions to exclude draughts which may
disturb the gas shield

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 • Joint and part access is not as good as MMA or TIG welding
• Cleanliness of base metal slag processes can tolerate greater
contamination.

2 Process Variables
The primary variables in MIG/MAG welding are:

• Welding current/wire feed speed

• Voltage
• Gases
• Travel speed and electrode orientation
• Inductance
• Contact tip to work distance
• Nozzle to work distance
• Shielding gas nozzle
• Type of metal transfer

2.1 Welding current / wire feed speed

On MIG/MAG welding sets there is no control to set the welding current. The
electrical characteristics of the welding set (flat or constant voltage type)
automatically alters the welding current with changes to the set wire feed
speed to achieve a constant arc length.

Increasing the wire feed, and therefore current, increases wire burn-off,
deposition rate and penetration.

Current type is almost always DC+ve, although some cored wires require
DC-ve for best results.

2.2 Voltage
This is set to achieve steady smooth welding conditions and is generally
increased as the wire feed speed is increased.

Increase in voltage increases the width of the weld and reduces penetration.

2.3 Travel speed and electrode orientation

The faster the travel speed the less penetration, narrower bead width and
the higher risk of undercut

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 • Increasing travel speed
• Reduced penetration and width,
undercut

Figure 2 The effect of travel speed.

Penetration Deep Moderate Shallow

Excess weld metal Maximum Moderate Minimum
Undercut Severe Moderate Minimum

Figure 3 The effect of torch angle.

2.4 Effect of contact tip to workpiece distance (CTWD)

The CTWD has an influence over the welding current because of resistive
heating in the electrode extension (see Figure 4). The welding current
required to melt the electrode at the required rate (to match the wire feed
speed) reduces as the CTWD is increased. Long electrode extensions can
cause lack of penetration, for example, in narrow gap joints, or with poor
manipulation of the welding gun. Conversely, the welding current increases
when the CTWD is reduced.

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 Contact tip

Gas nozzle

Contact tip
setback
Electrode
Contact tip-
Nozzle-to-work extension
to-work
(stand-off) distance
distance Arc length

Workpiece

Figure 4 Contact tip to workpiece distance; electrode extension;

and nozzle to workpiece distance.

Increased extension

Figure 5 The effect of increasing electrode extension.

The electrode extension should be checked when setting-up welding

conditions or when fitting a new contact tube. Normally measured from the
contact tube to the work piece (Figure 5) suggested CTWDs for the principal
metal transfer modes are:

Metal transfer mode CTWD, mm

Dip 10-15
Spray 20-25
Pulse 15-20

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2.5 Effect of nozzle to work distance
Nozzle to work distance (see Figure 4) has a considerable effect on gas
shielding efficiency; a decrease having the effect of stiffening the column.
The nozzle to work distance is typically 12-15mm. If the CTWD is
simultaneously reduced, however, the deposition rate at a given current is
decreased and visibility and accessibility are affected; so, in practice, a
compromise is necessary. The following gives suggested settings for the
mode of metal transfer being used

Metal transfer mode Contact tip position relative to nozzle

Dip 2mm inside to 2mm protruding
Spray 4-8mm inside
Spray (aluminium) 6-10mm inside

2.6 Shielding gas nozzle

The purpose of the shielding gas nozzle is to produce a laminar gas flow in
order to protect the weld pool from atmospheric contamination. Nozzle sizes
range from 13mm to 22mm diameter. The nozzle diameter should be
increased in relation to the size of the weld pool.

2.7 Types of metal transfer

Figure 6 Arc characteristic curve.

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 1) Dip transfer:

Key characteristics:
• Metal transfer by wire dipping or short circuiting into the weld pool
• Relatively low heat input process
• Low weld pool fluidity
• Used for thin sheet metal above 0.8 and typically less than 3.2mm,
positional welding of thicker section and root runs in open butt joints
• Process stability and spatter can be a problem if poorly tuned
• Lack of fusion risk if poorly set up and applied
• Not used for non-ferrous metals and alloys

In dip transfer the wire short-circuits the arc between 50–200 times/sec. This
type of transfer is normally achieved with CO2 or mixtures of CO2 and argon
gas + low amps and welding volts < 24V.

Figure 7 Dip transfer.

2) Spray transfer:

Key characteristics:
• Free-flight metal transfer
• High heat input
• High deposition rate
• Smooth, stable arc
• Used on steels above 6mm thickness and aluminium alloys above 3mm
thickness

Spray transfer occurs at high currents and high voltages. Above the
transition current, metal transfer is in the form of a fine spray of small
droplets, which are projected across the arc with low spatter levels. The high
welding current produces strong electromagnetic forces (known as the pinch
effect' that cause the molten filament supporting the droplet to neck down.
The droplets detach from the tip of the wire and accelerate across the arc
gap.

With steels it can be used only in down-hand butts and H/V fillet welds, but
gives significantly higher deposition rate, penetration and fusion than the dip
transfer mode. With aluminum alloys it can be used in all positions.

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 Figure 8 Spray transfer.

3) Pulsed transfer:

Key characteristics:
• Free-flight droplet transfer without short-circuiting over the entire working
range
• Very low spatter
• Lower heat input than spray transfer
• Reduced risk of lack of fusion compared with dip transfer
• Control of weld bead profile for dynamically loaded parts
• Process control/flexibility
• Enables use of larger diameter, less expensive wires with thinner plates -
more
• Easily fed (a particular advantage for aluminium welding)

Pulsing the welding current extends the range of spray transfer operation
well below the natural transition from dip to spray transfer. This allows
smooth, spatter-free spray transfer to be obtained at mean currents below
the transition level, eg 50-150A and at lower heat inputs.

A typical pulse waveform and the main pulse welding variables are shown in
Figure 9. Pulse transfer uses pulses of current to fire a single globule of
metal across the arc gap at a frequency between 50–300 pulses/sec. Pulse
transfer is a development of spray transfer that gives positional welding
capability for steels, combined with controlled heat input, good fusion, and
high productivity. It may be used for all sheet steel thickness >1mm, but is
mainly used for positional welding of steels >6mm.

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 Figure 9 Pulsed welding waveform and parameters.

4) Globular transfer:

Key characteristics:
• Irregular metal transfer
• Medium heat input
• Medium deposition rate
• Risk of spatter
• Not widely used in the UK; can be used for mechanised welding of
medium
• Thickness steels (typically 3-6mm) in the flat (PA) position

The globular transfer range occupies the transitional range of arc voltage
between free flight and fully short-circuiting transfer. Irregular droplet
transfer and arc instability are inherent, particularly when operating near the
transition threshold. In globular transfer, a molten droplet of several times
the electrode diameter forms on the wire tip. Gravity eventually detaches the
globule when its weight overcomes surface tension forces, and transfer
takes place often with excessive spatter

To minimise spatter levels, it is common to operate with a very short arc

length, and in some cases a buried arc technique is adopted. Globular
transfer can only be used in the flat position and is often associated with
lack of penetration, fusion defects and uneven weld beads, because of the
irregular transfer and tendency for arc wander.

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2.8 Inductance
What does inductance do?
When MIG welding in the dip transfer mode, the welding electrode touches
the weld pool, causing a short circuit. During the short circuit, the arc voltage
is nearly zero. If the constant voltage power supply responded instantly,
very high current would immediately begin to flow through the welding
circuit. The rapid rise in current to a high value would melt the short-circuited
electrode free with explosive force, dispelling the weld metal and causing
considerable spatter.

Inductance is the property in an electrical circuit that slows down the rate of
current rise (Figure 10). The current travelling through an inductance coil
creates a magnetic field. This magnetic field creates a current in the welding
circuit that is in opposition to the welding current. Increasing the inductance
will also increase the arc time and decrease the frequency of short-
circuiting.

For each electrode feed rate, there is an optimum value of inductance. Too
little inductance results in excessive spatter. If too much inductance is used,
the current will not rise fast enough and the molten tip of the electrode is not
heated sufficiently causing the electrode to stub into the base metal. Modern
electronic power sources automatically set the inductance to give a smooth
arc and metal transfer.

Figure 10 Relationship between inductance and current rise.

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3 Welding Consumables
3.1 Solid wires
Usually made in sizes from 0.6 to 1,6mm diameter they are produced with
an analysis which essentially matches the materials being joined. Additional
elements are often added especially extra de-oxidants in steel wires. C-Mn
and low alloy steel wires are usually copper coated to reduce the risk of
rusting and promote better electrical contact.

3.2 Flux cored wires

A cored wire consists of a metal sheath containing a granular flux. This flux
can contain elements that would normally be used in MMA electrodes and
so the process has a very wide range of applications.

In addition we can also add gas producing elements and compounds to the
flux and so the process can become independent of a separate gas shield,
which restricted the use of conventional MIG/MAG welding in many field
applications.

Most wires are sealed mechanically and hermetically with various forms of
joint. The effectiveness of the joint of the wire is an inspection point of cored
wire welding as moisture can easily be absorbed into a damaged or poor
seam.

Wire types commonly used are:

• Rutile – which give good positional capabilities.

• Basic – also positional but good on “dirty” material
• Metal cored – higher productivity and some having excellent root run
capabilities.
• Self-shielded – no external gas needed.

Baking of cored wires is ineffective and will do nothing to restore the

condition of a contaminated flux within a wire.

Note that unlike MMA electrodes the potential hydrogen levels and
mechanical properties of welds with rutile wires can equal those of the basic
types.

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4 Important Inspection Points/Checks When MIG/MAG
Welding
1 The welding equipment
A visual check should be made to ensure the welding equipment is in good
condition.

2 The eectrode wire

The diameter, specification and the quality of the wire are the main
inspection headings. The level of de-oxidation of the wire is an important
factor with single, double and triple de-oxidised wires being available.

The higher the level of de-oxidants in the wire, then the lower the chance of
porosity in the weld. The quality of the wire winding, copper coating, and
temper are also important factors in minimising wire feed problems.

Quality of wire windings and increasing costs

(a) Random wound. (b) Layer wound. (c) Precision layer wound.

3 The drive rolls and liner.

Check the drive rolls are of the correct size for the wire and that the
pressure is only hand tight, or just sufficient to drive the wire. Any excess
pressure will deform the wire to an ovular shape. This will make the wire
very difficult to drive through the liner and result in arcing in the contact tip
and excessive wear of the contact tip and liner.

Check that the liner is the correct type and size for the wire. A size of liner
will generally fit 2 sizes of wire ie (0.6 and 0.8) (1.0 and 1.2) (1.4 and 1.6)
mm diameter. Steel liners are used for steel wires and Teflon liners for
aluminium wires.

4 The contact tip

Check that the contact tip is the correct size for the wire being driven, and
check the amount of wear frequently. Any loss of contact between the wire
and contact tip will reduce the efficiency of current pick. Most steel wires are
copper-coated to maximise the transfer of current by contact between 2
copper surfaces at the contact tip, this also inhibits corrosion. The contact
tip should be replaced regularly.

5 The connections
The length of the electric arc in MIG/MAG welding is controlled by the
voltage settings. This is achieved by using a constant voltage volt/amp
characteristic inside the equipment. Any poor connection in the welding
circuit will affect the nature and stability of the electric arc, and is thus is a
major inspection point.

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 6 Gas and gas flow rate
The type of gas used is extremely important to MIG/MAG welding, as is the
flow rate from the cylinder, which must be adequate to give good coverage
over the solidifying and molten metal to avoid oxidation and porosity.

7 Other variable welding parameters

Checks should be made for correct wire feed speed, voltage, speed of
travel, and all other essential variables of the process given on the approved
welding procedure.

8 Safety checks
Checks should be made on the current carrying capacity, or duty cycle of
equipment and electrical insulation. Correct extraction systems should be in
use to avoid exposure to ozone and fumes.

A check should always be made to ensure that the welder is qualified

to weld the procedure being employed.

Typical welding imperfections:

1 Silica inclusions, (on ferritic steels only) caused by poor inter-run

cleaning.
2 Lack of sidewall fusion during dip transfer welding thick section
vertically down.
3 Porosity caused from loss of gas shield and low tolerance to
contaminants
4 Burn-through from using the incorrect metal transfer mode on sheet
metal

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