4/4/2018 GAS METAL ARC

WELDING
LAB REPORT # 4

Group Members:

Ahmad Ali Paracha (10)

Syed Jazib Abbas Zaidi (13)

Irsa Jahangir (28)

Usama Qamar Satti (31)

Khanzada Moiz Khan (40)

GROUP A2
WELDING AND JOINING PROCESSSES LAB # 4
INSTITUTE OF SPACE TECHNOLOGY, ISLAMABAD
DATE OF EXPERIMENT: 3/21/2018
DUE DATE: 4/4/2018
GAS METAL ARC WELDING

Table of Contents
Abstract ....................................................................................................................................................... 2
1. Introduction ......................................................................................................................................... 3
1.1. Modes of GMAW......................................................................................................................... 3
1.1.1. Short Circuit Mode / Dip Transfer Mode ............................................................................. 3
1.1.2. Globular Transfer Mode ....................................................................................................... 3
1.1.3. Spray Transfer Mode / Axial Spray Mode ............................................................................ 3
1.2. Difference Between SMAW and GMAW ................................................................................... 3
1.3. Types of Gases Used .................................................................................................................... 4
1.3.1. Inert Gases ............................................................................................................................ 4
1.3.2. Active Gases ......................................................................................................................... 4
1.4. Advantages ................................................................................................................................... 4
1.5. Disadvantages............................................................................................................................... 4
2. Objectives ............................................................................................................................................ 4
3. Apparatus ............................................................................................................................................. 4
4. Gas Metal Arc Welding Safety ............................................................................................................ 5
4.1. General Safety .............................................................................................................................. 5
4.2. Gas and Fume Hazards ................................................................................................................. 5
4.3. Gas and Fume Safety.................................................................................................................... 5
5. Experimental Procedure ...................................................................................................................... 6
5.1. Inspect Equipment & Set Machine............................................................................................... 6
5.2. Set Gas Pressure ........................................................................................................................... 6
5.3. Prepare Work Station ................................................................................................................... 6
5.4. Clamp Material............................................................................................................................. 6
5.5. Gun Positioning ............................................................................................................................ 7
5.6. Weld ............................................................................................................................................. 7
6. Results and Conclusions ...................................................................................................................... 7
7. References ........................................................................................................................................... 7

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Abstract
Gas metal arc welding is a welding technique which uses an electric arc to melt metal wire and join the
base metal together in gaseous environment. This process is also known as Metal Inert Gas Welding or
Metal Active Gas Welding (MIG/MAG). In this lab, all students performed gas metal arc welding under
the supervision of an instructor. The lab report shows a general introduction, apparatus, general safety,
gases and fume hazards and safety, procedure and results and conclusions from the analysis of the welding
technique.

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1. Introduction
Gas metal arc welding (GMAW) is a technique of welding in which gas is used as a shielding agent, metal
filler is used in the form of wire and arc is produced between the welding gun and workpiece for joining
purposes. It is a variation or shielded metal arc welding, but gas is used as flux rather than coated electrode
and wire filler is used rather than rod type filler. [1] [2]

Figure 1: GMAW Setup [1] Figure 2: GMAW Holding Gun [2]

1.1. Modes of GMAW

1.1.1. Short Circuit Mode / Dip Transfer Mode
Welding by this mode is called Microwire welding or pinch wire welding. This is used for thin sheets
because of less current and relatively less voltage is used in this mode. Metals forming the oxide layer are
weld in this mode because of less current so, heat is insufficient e.g. Al etc. DC current is mostly used in
this mode.
1.1.2. Globular Transfer Mode
Positive polarity is used, therefore DCEP is used for the formation of globules. Current and voltage is
higher. Active gases are avoided in this mode because of their bigger sized molecules due to which it
causes spattering e.g.CO2 is avoided. Flat, horizontal position are usually possible due to gravity, the drop
comes down.
1.1.3. Spray Transfer Mode / Axial Spray Mode
Gas flow is greater in this mode of GMAW. Highest current and voltage are used in this mode as compared
to other modes of the GMAW. Inert gases are usually used like Argon is used but Helium is not used it is
very light gas. Argon is used to due stability, it is spatter free and for the axial spray transfer. High
penetration because of smaller droplets so will go so far. Its suitable for the all position.
1.2. Difference Between SMAW and GMAW
Some of the differences are highlighted below:
 In SMAW, the electrode is a rod, and has a coating of flux for the shielding purposes, while in GMAW
wire is used as an electrode and gas is used in GMAW for shielding.
 GMAW uses gas shielding so slag is not produced on surface of weld, contrary to SMAW.
 Automatic feeding of filler is provided by GMAW machine, while manual feeding is required in
SMAW.

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1.3. Types of Gases Used

As in gas metal arc welding, the gases are used for the shielding. Two types of gases are used for that
purpose, which are as follows:
1.3.1. Inert Gases
Inert gases are usually used in GMAW for the shielding purpose, such as; N2, Ar, He etc.
1.3.2. Active Gases
Active gases are also used in GMAW such as; CO2, O2 (rarely) etc. Active gases aren’t used usually in
GMAW because they may react at high temperature but provide arc stability. These gases also reduce arc
deflection.
1.4. Advantages
Followings are some advantages of GMAW:
 No loss of filler metal.
 Deposition rate is not reduced due to continuously feed of wire.
 No discontinuity of weld.
 Greater arc intensity than SMAW.
1.5. Disadvantages
Some disadvantages are also there of GMAW such as:
 Not suitable for outdoors.
 It’s expensive than SMAW.
 More arc radiation.
 GMAW can’t be used on sheet workpieces.
2. Objectives
Main purpose of our experiment was:
 To learn the technique of Gas metal arc welding, along with all of apparatus specifications.
 To perform Gas metal arc welding, under the supervision of instructor.
 To take all necessary safety measures before the welding is performed.

3. Apparatus
The equipment required in this experiment is listed below:
 Welding Machine (MIG/MAG)
 Gas source (Argon Cylinder)
 Wire Reel (Filler)
 Work Piece
 Holding Gun
 Control System
 Wire Feed Drive Motor
The safety requirements for this experiment are:
 UV Protective Glasses
 UV Protective Helmet
 Leather Apron
 Leather Gloves
 Insulated Boots

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Figure 3: GMAW Holding Gun Figure 4: GMAW Machine

4. Gas Metal Arc Welding Safety

Safety is an important step in any experiment. Some safety measures in this experiment are given below
including general safety and with some emphasis on gases and fume safety.
4.1. General Safety
Following points should be kept in mind with reference to general safety.
 Keep insulation between the metal being weld or ground.
 Wear helmet to protect eyes form light
 Wear safety glasses
 Protective clothing.
 Don’t weld near water or combustible materials.
 Keep welding equipment away from flammable walls.
 Proper ventilation to remove dangerous fumes. [3]
4.2. Gas and Fume Hazards
Some hazard associated with gases and fumes are as follows
 Fumes causes burning of retina and inflammation of cornea of the eyes.
 Toxicity of fumes can cause permanent respiratory problems.
 Any gas if increased in quantity in the atmosphere can cause lack of oxygen, increasing risk.
 Carbon dioxide and ozone gases can be dangerous to work with. [4]
4.3. Gas and Fume Safety
Gas metal arc welding can dangerous if proper precautions are not taken.
 Welding Helmet should be worn so there is no direct contact with gases and fumes.
 Use respiratory protective equipment like filter masks or even oxygen masks if available.
 Excellent ventilation that will remove toxic fumes but keeping in mind the gas shielding should
not be disturbed otherwise the oxides will form.
 Inert gases should be used to reduce gas related hazards rather than active gases. CO 2 exposure for
long times can cause respiratory problems.
 Don’t put your head directly above the weld being made to lessen gas and fume exposure. [4]

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5. Experimental Procedure
5.1. Inspect Equipment & Set Machine
Before you begin, ensure the cables are not frayed or damaged. Turn machine on. Set voltage and wire
speed. [5]

Figure 5: Inspect Welding Machine [5]

5.2. Set Gas Pressure
Open valve counter-clockwise 1½ turns, monitoring the psi. Turn butterfly knob clockwise to set pressure.

Figure 6: Cylinder Adjustment [5]

5.3. Prepare Work Station
Use the steel and iron wire brush to clean debris from table. Ensure all oil is removed from materials to
be welded. Secure your workpieces using clamps and or magnets.

Figure 7: Work Station [5]

5.4. Clamp Material
Attach the work clamp to either the table, clamp or work piece to complete and ground the circuit.

Figure 8: Clamp material [5]

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5.5. Gun Positioning

On the gun, keep a distance between the end of nozzle and the wire 1/4”–3/8”.

Figure 9: Gun adjustment [5]

5.6. Weld
Keep material clean with the wire brush between welds.

Figure 10: Weld [5]

6. Results and Conclusions

With this type of welding all metals can be welded by some mode or the other without exception but
optimizations must be made for each method or mode. No slag is produced on welds so an additional step
of removing slag is unnecessary. The filler wire feed rate is automatic so, overall this method is easier and
user friendly than the other methods performed.

7. References
[1] Seminar Links, “Gas Metal Arc Welding (GMAW),” [Online]. Available:
https://www.slideshare.net/asertseminar/gas-metal-arc-welding-gmaw. [Accessed: 03-Apr-2018].
[2] “How to Improve Your Welds: Helpful hints for GMAW.” [Online]. Available:
https://www.thefabricator.com/article/arcwelding/how-to-improve-your-welds--helpful-hints-for-
gmaw. [Accessed: 03-Apr-2018].
[3] “MIG Welding Safety: Guide and Pictures,” Weld Guru. [Online]. Available:
http://weldguru.com/mig-welding-safety/. [Accessed: 03-Apr-2018].
[4] “MIG Welder Safety – GoWelding.Org.” [Online]. Available:
http://gowelding.org/welding/mig-gmaw/safety/. [Accessed: 03-Apr-2018].
[5] Miller Electric Mfg. Co., “Miller Owner’s Manual (MIG Welding).” [Online]. Available:
https://www.millerwelds.com/files/owners-manuals/O424F_MIL.pdf. [Accessed: 04-Apr-2018].

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