Mig Mag Welding Process

MIG / MAG WELDING PROCESS
What is Welding
Page no. 1
Page no. 2
1a. Basic Information of Welding Process
Welding is a metal joining process by :

Heating to temperature high enough to cause softening or melting
With or without application of pressure
With or without use of filler metal
Melting point same as metals being joined or melting point
ELECTRODE COATING
CORE WIRE
WELDING ATMOSPHERE
ARC STREAM
ARC POOL
SOLIDIFIED SLAG
PENETRATION DEPTH
WELD
BASE METAL
Elements in Welding Process
Page no. 3
Electrical Model of Welding Process
(+)
(+)
(-)
(-)
How Welding Takes Place ?

Stage - I
Stage - II
Stage - III
Torch
(+)
(-)
Electrode
Work Piece
(+)
Stage - IV
(+)
(+)
Weld Pool
(-)
(-)
Weldment
(-)
Stage I :- Electric Circuit remains open & no current flows though the circuit.
Stage II :- When the electrode strikes with work piece whether by operator or
some mechanical means (i.e. SPM / Robot) , electric circuit gets closed and
electrons flow from cathode to anode & Current flows from anode to cathode.
Electrical energy converts into power / heat energy using simple equation :Power / Heat = Current (I) x Voltage (V)
Page no. 4
Stage III :- Once the electric circuit is established between cathode & anode,
electrode is taken slightly backwards to establish the arc which allows the formation
of weld puddle / pool of homogenous material of molten electrode/filler & molten
work piece. Weld puddle is transferred on work piece by short circuiting effect of
Current & surface tension effect of molten metal. Thus Welding continues.
Stage IV :- When the welding is completed , Electrode is taken backwards
smoothly to terminate electric circuit.
Electrical Polarity : - Depending upon how the electrical circuit is completed
in welding & Types of output current , Welding Process is classified into following
Output Current
Alternating Current (AC)

- Polarity changes after half cycle
Direct Current (DC)

-Polarity remains constant through
out the welding
-Widely used across the industry
Types of Polarity in DC
Straight Polarity
i.e. Direct Current Electrode
Negative (DCEN)
Reverse Polarity
i.e. Direct Current Electrode Positive
(DCEP)
Application :
1. TIG Welding
Application :
1. GMAW
2. MIG / MAG Welding
Page no. 5
Typical Welding Set up of Arc Welding
Typical Set up :1. Constant Voltage (CV)

Welding Power Source
2. Power Cord
3. Weld Cable to Wire Feeder
4. Ground Cable to Work Piece
5. Work Piece
6. Welding Gun
7. Constant Speed Wire Feeder
8. Electrode Wire
9. Gas hose
10. Shielding Gas Cylinder
1. Welding Power Source :- Function of Welding Power Source is to

establish welding circuit and provide electrical energy (i.e. Current
& Voltage)
a) Current :- Electric current is the flow of electric charge i.e. electrons. It is
measured in Amperes (Amp). Electric current is displayed on welding Power Source
b) Voltage :- It is the potential difference between cathode & Anode which
Provides the electromotive force between cathode & anode for electrons to flow.
It is measured in Volt (V). Welding power source has display for Welding Voltage
2. Power Cord :- Cable used to connect anode & cathode.

3. Weld Cable to Wire Feeder :- Cable used to provide drive to feeder.
4. Ground Cable to Work piece :- -Ve / +Ve Cable used to provide
earthing to work piece.
Page no. 6
5. Work piece :- Welding is done on work piece.

Different weld joints used of work piece are described below:-
6. Welding Gun :- Function of welding gun is to direct the welding electrode into
weld pool. It works as anode or cathode of welding circuit.
Diffuser
Page no. 7
7. Constant speed wire feeder :- It provides drive to the welding electrode to

feed into weld pool at constant set speed.
8. Electrode Wire :- A metal or alloy in rod or wire forms used in electric arc
welding to maintain the arc and at the same time supply molten metal or alloy at
the point where the weld is to be accomplished.
As per American Welding Society (AWS), the welding electrodes are designated as
follows:Solid / Cored
ER XX X
Electrode Rod
Strength
X
Chemical
Composition
Example :-
Electrode
70
Tensile Strength
70,000 psi
(480 Mpa)
S
Solid
wire
6
Chemical
Properties
as per No.6
Page no. 8
Type of Welding Electrodes
Solid
Electrode
Flux Cored
Electrode
Metal Cored
Electrode
9. Gas hose :-Tube through which the shielding gas flows at welding pool
10. Shielding Gas :-Shielding gas works as molten metal protection media
so that molten metal does not react with atmosphere.
During fusion welding, the molten metal in the weld puddle is susceptible to
oxidation. So it should be protected from atmosphere by use of :
Weld Fluxes (e.g. SiO2, TiO2, FeO, MgO, Al2O3)
Inert Gases (e.g. Ar, He, N & CO2)
Vacuum
Gas Supply System :
Flow
meter
Pre-heater
Page no. 9
Welding Position
ISO / ASME Welding Positions for Different Weld Joints :Plate to Plate Weld Joint :-
Down hand:
PA/1G
Horizontal-Vertical:
PC/2G
Overhead:
PE/4G
Vertical-up:
PF/3G
Vertical-Down:
PG/3G
Down hand:
PA/1F
Horizontal:
PB/2F
Overhead:
PD/4F
Vertical-up:
PF/3F
Vertical-Down:
PG/3F
Page no. 10
Pipe to Pipe Weld Joint :-
Pipe rotates with

axis horizontal,
Welding down
hand: PA/1G
Pipe fixed with

axis vertical,
Welding
horizontal-vertical:
PC/2G
Pipe fixed with

axis horizontal,
Welding
upwards:
PH/5G
Pipe
Fixed with axis Pipe fixed with axis
under 45 deg angle ,
Horizontal,
welding upwards:
welding
H-LO45 / 6G
downwards:
PJ/5G
Pipe to Plate Weld Joint :-
Pipe rotates with

axis horizontal,
Welding down
hand: PB/2FR
Pipe fixed with

axis vertical :
PB/2F
Pipe fixed with

Axis vertical,
Welding
overhead:
PD/4F
Pipe
Pipe fixed with axis
Fixed with axis
Horizontal ,
Horizontal,
Welding
welding
downwards:
Upwards:
PJ / 5F
PH/5F
Page no. 11
Welding Defects & Causes

A flaw or flaws that by nature or accumulated effect render a part or
product unable to meet minimum applicable acceptance standards or
specifications.
Common Welding Defects
Sr.
No.
Defect
Lack of
Fusion
Shabby Weld
Bead
Excessive
Spatters
Under Cut
Blow Holes
Definition
Image
Causes
When fusion in any plate

occurs less than
specifications (min 25% of
min material thk)
-Low current
-High voltage
-Excessive speed
-Torch orientation not
correction
-Torch position not
correct
Weld bead which does not

look uniform throughout
the welding
-Unsteady hand
movement by
operator
- More stick out
Length
Spillage of molten metal at

the time of welding on the
work piece
-Excessive current,
voltage & Speed
-Unsteady Hand
movement
-More stick out length
A portion where a bead is

not filled, forming a
groove in the base metal
along the toe of a weld
-Excessive current
-Excessive stick out
-Slow Speed
Spherical cavity in a bead
-Insufficient gas flow

-Surface irregularities
e.g. oil, rust, moisture
-Inadequate torch
angle

Sr.
No.
Defect
In sufficient
Leg Length
Weld Cracks
Silica Island
(Glass Bead)
Weld Lump
Definition
Image
Page no. 12
Causes
Leg Length : Distance

between the root of a joint
and the toe of a fillet weld
-Torch orientation not

correct
-Torch position not
correct
A discontinuity
characterized by a break
or gap in the surface of a
weld
-Raw material too

brittle
-Hydrogen
embrittlement
Silicon Oxide formed on

welding bead surface
which looks glassy
-Insufficient gas flow

-Gas composition not
as per standard
-More silicon content
in welding wire
Excessive welding done at

particular point where the
Leg length is more than the
specified
-Excessive wire feed

speed
-Travel speed too
slow
Page no. 13
Measuring Parameters for Welding Quality

Welding Bead Geometry
X
Convex Weld Bead
Plate 2
Concave Weld Bead
P2
P1 : Penetration Depth on Plate 1
P2 : Penetration Depth on Plate 2

A : Throat Depth
L2
L1 : Leg Length on Plate 1
L2 : Leg Length on Plate 2

P1
Plate 1
L1
Section - XX
B : Bead Width
Page no. 14
1b. Various Types of Welding Process

Welding Process broadly classified into following category :A) Fusion Welding or Non-Pressure Welding :- The material at the joint
is heated to a molten state & allowed to solidify.
Fusion / Arc Welding
Carbon
Arc
Metal
Arc
Metal
Inert Gas
Tungsten
Inert Gas
Plasma
Arc
Submerge
Arc
Electro
Slag
B) Plastic Welding or Pressure Welding :- The piece of metal to be joined

are heated to a plastic state & forced together by external pressure
Pressure / Resistance Welding
Flash Butt
Spot
Seam
Projection
Percussion
Page no. 15
C) Thermit Welding
D) Solid State Welding

Solid State Welding
Friction
Ultrasonic
E) Latest Welding Processes
Electron - Beam
Laser
F) Low Heat Input Welding Processes
Brazing
Soldering
Diffusion
Explosive
Page no. 16
1a. Basic Information of MIG / MAG Welding Process

Definition
MIG / MAG Welding is a type of Gas Metal Arc Welding (GMAW) Process which
produces the coalescence of metal by heating them with an arc between a
continuously fed filler metal electrode and the work piece.
Depending upon the combination of gas & action it performs while welding,
Process is divided in two category: Metal Inert Gas Welding (MIG) :- If the shielding gas used is an inert gas
such as argon or helium then it is termed as metal inert gas (MIG) welding.
Metal Active Gas Welding (MAG) :- if shielding gas is active gas such as CO2
or mixture of inert and active gases then process is termed as metal active
gas (MAG) welding.
Principle of MIG/MAG welding
Heat generated by the electric arc melts the surfaces of the base metal to
develop a weld joint. The arc is generated between the base metal and the
electrode. Welding arc and weld pool are well protected by a jet of shielding gas
coming out of the nozzle and forming a shroud around the arc and weld.
Consumable electrode is feed automatically while the torch is controlled manually
or automatically.
Applicability of MIG / MAG Welding ranges widely for Carbon Steel, Stainless
Steel, Aluminium, Magnesium, Copper, Nickel, silicon, bronze, and tubular metal
cored surfacing alloys.
Page no. 17
Advantages :1.
2.
3.
4.
5.
6.
7.
8.
The ability to join a wide range of material types & Thicknesses.

Higher Deposition rate of welding electrode.
Excellent Weld Bead Appearance
Easily adopted for high-speed robotic & semi automatic applications
Feasibility in all position welding
Lower hydrogen weld deposit generally less than 5 mL / 100 g of weld metal
No need for slag removal
Less welding fumes as compared to SMAW & FCAW process
Limitations :1.
Higher skilled welder is required
2.
Shielding of weld pool 100% from external environment becomes difficult which
leads to formation of silica island (Glass Bead) defect.
3.
Part to Part matching accuracy requirement is stringent to get the specified weld
bead geometry by MIG / MAG Welding Process i.e. process capability less to
bridge the gap.
Page no. 18
Metal Transfer in MIG/MAG welding

Short Circuit Transfer
Globular Transfer
Short circuit transfer refers

to the welding wire actually
short circuiting the base
metal 90-200 times per
second. Wire feed speed,
voltages and deposition
rates are lower than other
types.
Globular transfer is the

state of transfer between
short circuit and spray arc
transfer. Large globs of
wire are expelled and enter
the weld pool. Results
when welding parameters
are higher than the short
circuiting.
Short circuit metal transfer

is very versatile in allowing
the welder to weld on thin
or thick metal in any
position.
Limitations
Low metal deposition
rate
Lack of fusion on
thicker materials
More spatters
Limitations
Presence of spatters
Less desirable weld
appearance
Limited to flat and
horizontal fillet weld
position..
Limited to metals 3
mm or thicker.
Spray Arc Transfer
Spray arc transfer sprays

a stream of molten droplets
across the arc, from the
electrode wire to the base
metal.
Used
typically
higher voltage, wire feed
speed and amperage values
than short circuit transfer.
Advantages
High deposition
Good
fusion
and
penetration
Good bead appearance
Presence of very little
spatter.
Limitations
Used only on metals 3
mm and thicker.
Limited to flat and
horizontal fillet weld
position.
Good fit-up is always
required.
Page no. 19
1c. Input Material Condition

1.
Input material must be free from oil & rust
2.
Maximum permissible gap between two matting part is 80% of wire diameter
3.
Input parts must qualify the PQS / CTQ parameters.

- Pipes Qualify to Relation Gauge
- Sheet Metal Parts / Sub Assembly Qualify to Relation Gauge
4.
Particularly for Robotic Welding Application, the maximum allowable variation in

trim line is +/- 0.8 mm.
Page no. 20
1f. Method
Stick Out :Robotic torch configuration with respect to to work piece: Following figure shows
typical configuration of welding torch with respect to work piece
Fig : Robotic Torch configuration & Wire Stick Out

Wire stick out shall be maintained in the range of 12-15 times wire diameter
(e.g. for wire diameter 1.2 mm, wire stick out of about 18 mm to be
maintained).
Weld Torch Angle/Orientation
Weld torch angle for welding is very crucial to get required penetration and
strength at weld joint. The angle / orientation (W, P & R values) should be
recorded for reference.
Page no. 21
Travel angle refers to the angle in which welding takes place. This angle
should be between 0-10 degrees.
Travel angle may be either a push angle or a drag (Pull) angle, depending on
the position of the torch. When the torch is ahead of the weld, it is known as
pulling (or dragging) the weld. When the torch is trailing the weld, it is known
as Push Weld.
Work Angle is the angle of torch from vertical to the weld direction, which is
to be kept as 45 +/- 5 Deg.
Maximum allowable Torch position wrt to Weld Joint Center Point is 80% of
Wire Diameter.
Efforts should be made to weld all joints in down hand position so as to

prolong / prevent chocking of nozzle with weld spatters.
Push angle gives better weld finish but lower penetration as compared to pull
angle. Ascent welding gives deeper penetration with narrower weld bead
where as descent welding gives shallower penetration with flatter weld bead.
Page no. 22
Direction of travel changes slightly when welding in the vertical position to 010 deg.
Weld Parameters
a) Weld Current : Increased welding current gives more weld deposition and
deeper penetration
b) Weld Voltage : Increased welding voltage gives flatter bead & reduced
penetration & vice versa.
Page no. 23
c) Welding Speed : As a higher speed is used, the bead width decreases, the
depth of penetration decreases, and the reinforcement of weld decrease. Weld
speed to be optimized to get the desired weld bead and penetration.
d) Gas Flow Rate : Specified gas flow rate range : 12-15 LPM
Too Less gas flow rate causes blow holes
Too excess gas flow rate causes arc to become unstable.
Page no. 24
1i. Measurement
S
N
1a
1b
Term
Penetration Depth
Penetration
Evaluation Range
Explanatory
illustration
BE IS P-001-00
Definition
Fillet Joint
Distance between
a) Lower Limit Average 30
the top of a base
% of Minimum Thickness
metal fused part and
b)
Upper Limit 100% of
the surface to be
Minimum Thickness
welded
Length of welding
after leaving the
start and end bead
shape
Except for Temporary welding,

penetration should be checked
for a length measured between
center of the welding start point
and the center of the welding end
point
a)
1c
No of Sections
Sections taken for

penetration
checking along the
Evaluation Range
Minimum Bead
Thickness
Length from the

root of a weld crosssection to a point on
the bead surface at
the shortest distance
b)
1 section to be checked at
center if weld length <=
150 mm
For weld length >150 mm,
1 section to be cut at center
and remaining sections at
75 mm distance away from
center
Minimum Equal to Plate

Thickness
Lower Limit 5 mm
Minimum Bead
Width
Minimum width
between bead
surfaces
Upper Limit 7 mm
Distance between
the root of a joint
and the toe of a
fillet weld
Leg Length
A portion where a
bead is not filled,
forming a groove in
the base metal along
the toe of a weld
A portion where a
bead is not fused
with the base metal
and overlaid at the
toe of a weld
Under cut
Overlap
13
Minimum Equal to Plate

Thickness
Depth : 0.5 mm or less
The bead end shall be smooth

(Not Steep)
Width : approx. 1 mm or less
Blow Holes
Cavity with 1 mm or large

diameter is not acceptable. Five or
Spherical cavity in a
less cavities per cross-section
bead
surface are acceptable.
(Cavity with 0.2 mm or smaller
diameter shall not be counted)
Bead Joint
Minimum required
lap length for bead
joint
15 mm
12
Page no. 25
Lap dimension : 5 mm or more
Weld tack position
Tacking to be done 15 mm away

Position of tack along
from start and end point of trim
the weld length
line of component
Weld Tack Geometry
Diameter of tack should not

Diameter and Height
exceed 6 mm and height should be
of Tack
4-6 mm
16
18
Page no. 26
Over Run
Extra Length of welding

Critical Weld joints must be
before the start and after the completed with 10 mm over runs at
end point of trim line of
start and end points
component
Hardness of
HAZ
HAZ - The portion of the

Hardness of weld bead & HAZ shall
base metal that has not
not exceed 400 HV1. HAZ hardness
been melted, but its
shall be checked at 0.1 mm from
mechanical properties have
weld bead and average of three
been altered by the heat of
readings to be taken.
welding

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MIG / MAG WELDING PROCESS