Abstract
The operational characteristics of gas metal arc welding (GMAW) process influencing the behavior of weld with respect to its geometry, microstructure and defects has been described. It is presented in reference to the behavior of metal transfer , thermal characteristics of the process and thermal description of the weld. Three primary mode of metal transfer from electrode tip commonly known as short circuit , globular and spray transfer as a function of current and voltage of the GMAW process have been explained. Thermal behavior of the entire system which is basically responsible to govern the weld characteristics has been described in terms of the cause considered as thermal characteristics of the process and its effect as thermal behaviour of the weld. The thermal characteristics of the process are analytically stated in terms of melting of filler wire and thermal nature of metal transfer. The thermal description of weld is analytically discussed with respect to the effects of heat flow, fluid flow and metal transfer. The weld characteristics considered in terms of its geometry, microstructure and defects are primarily discussed in terms of the behavior of deposition and flow of liquid metal followed by the mechanism of its solidification.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Gourd, L.M. : Principles of Welding Technology, p. 32. English Language Book Society, Edward Arnold Ltd., (1986)
Mathison, Jerry : Understanding transfer modes for GMAW. Pract. Weld. Today 14 (2008)
Kim, Y.S., Eagar, T.W.: Analysis of metal transfer on gas metal arc welding. Weld. J. 72(7), 269s–278s (1993)
Heald, P.R., Madigan, R.B., Siewert, T.A., Lin, S.: Mapping the droplet transfer modes for an ER-1000 S-1 GMAW electrode. Weld. J. Res. Suppl. 73, 38s–43s (1994)
Johnson, J.A., Carlson, N.M., Smart, H.B., Clark, D.E.: Process control of GMAW: sensing of metal transfer mode. Weld. J. Res. Suppl. 70, 91s–99s (1991)
Liu, S., Siewert, T.A.: Metal transfer in gas metal arc welding: droplet rate. Weld. J. 68, 52s–58s (1989)
Lyttle, K.A.: GMAW—a versatile process on the move. Weld. J. 62(3), 15–23 (1983)
Wilson, Eric.: Welding technology data sheet, 60 metal inert gas arc welding—Part 4. Weld. Met. Fab. 14, 5, 165–172 (1982)
Craig, E.: A unique mode of GMAW transfer. Weld. J. 66(9), 51–55 (1987)
Matthews, J.R., Lassaline, E.E., Porter, J.F., Leewis, K.G.: Evaluating frequency modulated GMA welding for HY 80 steel. Weld. J. 71(9), 49–53 (1992)
Norrish, J., Richardson, I.F.: Metal transfer mechanisms. Weld. Met. Fab. 20(1), 17–22 (1988)
Waszink, J.H., Graat, L.H.J.: Experimental investigation of the forces acting on a drop of a weld metal. Weld. J. 62(4), 108s–116s (1983)
Essers, W.G., Van Gompal, M.R.M.: Arc control with pulsed GMA welding. Weld. J. 63(6), 26–32 (1984)
Stenbacka, N., Persson, K.A.: Shielding gases for gas metal arc welding. Weld. J. 68(11), 41–47 (1989)
Loh, P.C., Loper, C.R., Gregory, J.T.: Gas metal arc welding of HK 40 steel. Weld. J. 70(11), 31–36 (1991)
Rhee, S., Kannatey–Asibu, E.: Observation of metal transfer during gas metal arc welding. Weld. J. 71(10), 381s–386s (1992)
Quinn, T.P., Madigan, R.B., Siewert, T.A.: An electrode extension model for gas metal arc welding. Weld. J. 73(10), 241s–247s (1994)
Amin, M., Ahmed, N.: Synergic control in MIG welding. Met. Constr. 19(1), 22–28 (1987)
Lancaster, J.F.: The Physics of Welding, IIW, 1st edn, pp. 134–230. Pergamon Press, New York (1984)
Smart, H.B., Einerson, C.J.: A model for heat and mass input control in GMAW. Weld. J. 72(5), 217s–229s (1993)
Allum, C.J., Quintino, L.: Control of fusion characteristics in pulsed current MIG welding. Part-II, Simple model of fusion characteristics. Met. Constr. 17(5), 314R–317R (1985)
Colombieer, L., Hochmann, L. : Stainless Heat Resisting Steels, pp. 68–69. Edward Arnold Publishers Ltd., (1967)
Kent, Von Horn R.: Aluminium Properties and Physical Metallurgy, pp. 17–181. American Society for Metals, Metals Park, Ohio (1967)
Maruo, H., Hirata, Y.B.: Study of Pulsed MIG Welding, IIW Doc. SG 212-585-84. Welding Department, Osaka University, Japan, July (1984)
Metals Handbook, vol. 3, 9th Ed.. ASM International, Metals Park, Ohio (1979)
Metals Handbook : Properties and Selection: Nonferrous Alloys and Pure Metals. ASM International, Metal Park, Ohio, 10th Ed., 2, 1099 (1979)
Tekriwal, P., Mazumder, J.: Finite element analysis of 3-Dimensional transient heat transfer in GMA welding. Weld. J. 67, 150s–156s (1988)
Waszink, J.H., Piena, M.J.: Experimental investigation of drop detachment and drop velocity in GMAW. Weld. J. 65(11), 289s–298s (1986)
Waszink, J.H., Van Den Heuvel, G.J.P.M.: Heat generation and heat flow in the filler wire in GMAW welding. Weld. J. 61(8), 269s–282s (1982)
Kim, Y.S., Mceligot, D.M., Eagar, T.W.: Analysis of electrode heat transfer in gas metal arc welding. Weld. J. 70(1), 20s–31s (1991)
Jilong, Ma., Apps, R.L.: Analysing metal transfer during MIG welding. Weld. Metal Fab. 15(4), 119–128 (1983)
Rosenthal, D.: The theory of moving sources of heat and its application to metal treatments. ASME Trans. 68, 849–866 (1946)
Goldak, J., Chakravarti, A., Bibby, M.: A new finite element model for welding heat sources. Met. Mater. Trans. 15B, 299–305 (1984)
Jeong, S.K., Cho, H.S.: An analytical solution to predict the transient temperature distribution in fillet arc welds. Weld. J. 76, 223s–232s (1997)
Komanduri, R., Hou, Z.B. : Thermal Analysis Of The Arc Welding Process: Part I. General solutions. Met. Mater. Trans. 31B, 1353–1370 (2000)
Nguyen, N.T., Ohta, A., Matsuoka, K., Suzuki, N., Maeda, Y.: Analytical solutions for transient temperature of semi infinite body subjected to 3–D moving heat sources. Weld. J. 78, 265s–274s (1999)
Wells, A.A.: Heat flow in welding. Weld. J. 31, 263s–267s (1952)
Apps, R.L., Milner, D.R.: Heat flow in argon arc welding. Br. Weld. J. 34, 475–485 (1955)
Paley, Z., Lunch, J.N., Adams Jr., C.M.: Heat flow in welding heavy steel plate. Weld. J. 43, 71s–79s (1964)
Christensen, N., de Davies, L., Gjermundsen, K.: Distribution of temperatures in arc welding. Br. Weld. J. 12(2), 54–75 (1965)
Pavelic, V., Tanbakuchi, R., Uyehara, O.A., Myers, P.S.: Experimental and computed temperature histories in gas tungsten arc welding of thin plates. Weld. J. 48, 295s–305s (1969)
Kou, S.: Simulation of heat flow during welding of thin plates. Met. Mater. Trans. 12A, 2025–2030 (1981)
Kou, S., Kanavsky, T., Fyfitch, S.: Welding thin plates of aluminium alloys—a quantitative heat flow analysis. Weld. J. 61, 175s–181s (1982)
Wilson, E.L., Nickell, R.E.: Application of the finite element method to heat conduction analysis. Nucl. Eng. Design 4, 277–286 (1966)
Paley, Z., Hibbert, P.D.: Computation of temperature in actual weld design. Weld. J. 54, 385s–392s (1975)
Friedman, E. : Thermodynamic analysis of the welding process using the finite element method. Trans. ASME J. Press. Vessel Technol. 206–213 (1975)
Friedman, E., Glickstein, S.S.: An investigation of the thermal response of stationary gas tungsten arc welds. Weld. J. 55, 408s–420s (1976)
Tsai, C.L., Lee, S.G., Shim, Y.L., Jaeger, J.J., Chasten, C.P.: ASME Heat Transfer in Materials Processing, (JHTD), 224, 9–17 (1992)
Tsai, C.L. : American Society of Metals Conference on Trends in Welding Research in the United States, New Orleans, LA, pp. 91–108. ASM International, Metal Park, OH (1982)
Nunes Jr., A.C.: An extended Rosenthal weld model. Weld. J. 62(6), 165s–170s (1983)
Eagar, T.W., Tsai, N.S.: Temperature fields produced by travelling distributed heat sources. Weld. J. 62(12), 346s–355s (1983)
Na, S.J., Lee, S.Y. : A study of the three dimensional analysis of the transient temperature distribution in gas tungsten arc welding. In: Proceeding of Institute of Mechanical Engineering (London), Part B 201, pp. 149–156 (1987)
Prasad, N., Silva, Sankara, Narayanan, T.K.: Finite element analysis of temperature distribution during arc welding using adaptive grid technique. Weld. J. 75, 123s–128s (1996)
Tekriwal, P., Mazumder, J.: ASM International Conference on Proceedings of Trends in welding research, Gatlinburg, TN. ASM International, Metal Park, OH, (1986)
Boo, K.S., Cho, H.S. : Transient temperature distribution in arc welding of finite thickness plates. In: Proceeding of Institute of Mechanical Engineering Part B 204, pp. 175–183 (1990)
Ule, R.L., Joshi, Y., Sedy, E.B.: A new technique for three dimensional transient heat transfer computations of autogenous arc welding. Met. Mat. Trans. 21B, 1033–1047 (1990)
Kasuya, T., Yurika, N.: Prediction of welding thermal history by a comprehensive solution Weld. J. 72, 107s–115s (1993)
Kasuya, T., Yurika, N.: Determination of necessary preheat temperature to avoid cold cracking under varying ambient temperature. ISIJ Int. 35(10), 1183–1189 (1995)
Zacharia, T., Eraslan, A.H., Aidun, D.K.: Modeling of autogenous welding. Weld. J. 67, 53s–62s (1988)
Zacharia, T., Eraslan, A.H., Aidun, D.K.: Modeling of non autogenous welding. Weld. J. 67, 18s–27s (1988)
Saha, S.C., Ghosh, A.K., Malhotra, S.L.: Heat transfer in welding—a numerical approach. Indian Weld. J. 26(4), 8–12 (1993)
Nguyen, N.T., Mai, Y.W., Simpson, S., Ohta, A.: Analytical approximate solution for double ellipsoidal heat source in finite thick plate. Weld. J. 83, 82s–93s (2004)
Pathak, A.K., Datta, G.L.: 3-D finite element analysis on heat flow in welding under varying arc lengths. Indian Weld. J. 33, 4, 24–29 (2000)
Pathak, A.K., Datta, G.L.: Three dimensional finite element analysis of heat flow in arc welding. Indian W. J. 32(3), 32–38 (1999)
Christensen, K.H., Sorensen, T., Al-Erhayem, O.: A neural network approach for GMA butt joint welding. In: Proceeding of 11th International Conference on Joining of Materials, JOM Institute for the Joining of Materials, p. 8. Gilleleje, Denmark (2003)
Oreper, G.M., Eagar, T.W., Szekely, J.: Convection in arc weld pools. Weld. J. 62, 307s–312s (1983)
Oreper, G.M., Szekely, J.: Heat and fluid flow phenomena in weld pools. J. Fluid Mech. 147, 53–79 (1984)
Kou, S., Wang, Y.H.: Weld pool convection and its effect. Weld. J. 65, 63s–70s (1986)
Hong, K., Weckman, D.C., Strong, A.B., Zheng, W.: Modelling turbulent thermofluid flow in stationary gas tungsten arc weld pools. Sci. Technol. Weld. Joining 7(3), 125–136 (2002)
Sahoo, S.K., Roy, G.G.: Mathematical modelling of fluid flow and heat transfer during fusion welding: Some case studies, Procd. Seminar on Advances in Welding Technology (Weld Tech–2003), pp. 26–41. IIT Kharagpur, 14–15 March 2003
Zhang, W., Roy, G.G., Elmer, J.W., DebRoy, T.: Modeling of heat transfer and fluid flow during GTA spot welding of 1005 steel. J. App. Phys. 93, 5, 1, 3022–3033 (2003)
Tsao, K.C., Wu, C.S.: Fluid flow and heat transfer in GMA weld pools. Weld. J. 67, 70s–75s (1988)
Ushio, M., Wu, C.S.: Mathematical modelling of three dimensional heat and fluid flow in a moving Gas Metal Arc weld pool. Met. Mater. Trans. 28B, 509–516 (1997)
Kim, I.S., Basu, A.: A mathematical model of heat transfer and fluid flow in gas metal arc welding process. J. of Mater. Process. Technol. 77, 17–24 (1998)
Sun, J.S., Wu, C.S., Gao, J.W.: Modelling the weld pool behaviours in GMA welding. Int. J. Joining Mater. 11(4), 112–117 (1999)
Kumar, S., Bhaduri, S.C.: Theoretical investigation of penetration characteristics in gas metal arc welding using finite element method. Met. Mater. Trans. 26B, 611–624 (1995)
Kumar, S., Bhaduri, S.C.: Three dimensional finite element modeling of gas metal arc welding. Met. Mater. Trans. B 25B, 435–441 (1994)
Pardo, E., Weckman, D.C. : The interaction between process variables and bead shape in GMA welding: a finite element analysis, recent trends in welding science and technology. In: 2nd International Conference of Welding Research, pp. 391–395, 14–18 May 1989
Essers, W.G., Walter, R.: Heat transfer and penetration mechanisms with GMA and plasma- GMA welding. Weld. J. 60(2), 37–42s (1981)
Dimbylow, C.S.: Bead geometry and properties of inconel 625 overlays on steel. Metal Constr. 17(1), 35–39 (1985)
McGlone, J.C.: Weld bead geometry prediction—a review. Metal Constr. 14(7), 378–384 (1982)
David, S.A., Liu, C.T.: High-power laser and arc welding of thorium-doped iridium alloys. Weld. J. 61, 157–163s (1982)
Davies, G.J., Garland, J.G.: Solidification structures and properties of fusion welds. Int. Met. Rev. 20, 83–105 (1975)
Savage, W.F.: Solidification, segregation and weld imperfections. Weld. World 18, 89–133 (1980)
Kerr, H.W., Villafuerte, J.C.: Metal Science of Joining (Cieslak, M.J., Perepezko, J.H., Kang, S., Glicksman, M.E. eds.), p. 11. The Minerals, Metals and Materials Society, Warrendale, PA (1992)
David, S.A., Vitek, J.M., Rappaz, M., Boatner, L.A.: Microstructure of stainless steel single crystal electron beam welds. Metall. Trans. 21A, 1753–1766 (1990)
Rappaz, M., David, S.A., Vitek, J.M., Boatner, L.A.: Development of microstructures in Fe–15 Ni–15 Cr single-crystal electron beam welds. Metall. Trans. A 20A, 1125–1138 (1989)
Rappaz, M., David, S.A., Vitek, J.M., Boatner, L.A.: Analysis of solidification microstructures in Fe–Ni–Cr single crystal welds. Metall. Trans. A 21A, 1767–1782 (1990)
Easterling, K.: Introduction to Physical Metallurgy of Welding. Butterworth Publications (1985)
Harrison, P., Ferrar, Roy: Microstructural development and toughness of C–Mn and C–Mn–Ni weld metal; Part—I. Metal Constr. 19(7), 392–399R (1987)
Lancaster, J.F., Metallurgy of Welding, pp. 144–229. Allen and Unwin (Publishers) Ltd (1987)
Reed-Hill, Robert E.: Physical Metallurgy Principles. Affiliated East West Press Pvt. Ltd., New Delhi (1973)
David, S.A., Vitek, J.M.: Int. Mater. Rev. 34, 213–245 (1989)
DebRoy, T., David, S.A.: Physical processes in fusion welding. Rev. Mod. Phys. 67(1), 85–112 (1995)
Garland, G.J.: The control of weld pool solidification. Ph.D. thesis, University of Cambridge, UK, (1972)
Matsuda, F., Hashimato, T., Senda, T.: Fundamental investigations of solidification structure in weld metal. Trans. Natl. Res. Inst. Met. (Jpn) 11(1), 43–58 (1969)
Nippes, E.F., Savage, W.F., Grotke, G.: Further studies of the hot-ductility of high-temperature alloys. Weld. Res. Council. Bull. 33, 1 (1957)
Nippes, E.F., Wawrousek, H., Fleishman, W.L.: The heat-affected zone in arc-welded Type 347 stainless steel. Weld. J. 34(4), 169–182s (1955)
Rappaz, M., Carrupt, B., Zimmerman, M., Kurz, W.: Numerical-simulation of eutectic solidification in the laser treatment of materials. Helv. Phys. Acta 60, 924–936 (1987)
Rappaz, M., Gremaud, M., Dekumbis, R. and Kurz, W.: Laser Treatment of Materials (Mordike, B.J., ed.) DGM Informationsgesellschaftverlag, Bad Nauheim, FRG, (1987)
Biloni, H.: Physical Metallurgy, Part I (Chan, R.W., Haasen, P., eds.), pp. 478–579. Elsevier, New York (1983)
Flemings, M.C.: Solidification Processing. McGraw Hill, New York (1974)
Kurz, W., Fisher, D.J.: Fundamentals of solidification. Trans Tech Publications, Aedermannsdorf, Switzerland (1986)
Glickman, M.E.: Principles of Solidification and Materials Processing, Vol. I, p. 11 (Trivedi, R., Sekhar, J.A., Mazumder, J., eds.). Oxford & IBH, Publishing Co. Pvt. Ltd., New Delhi (1989)
Brooks, J.A., Baskes, M.I.: Advances in Welding Science and Technology (David, S.A., ed.), p. 93. ASM International, Metals Park, OH (1986)
Easterling, K.E.: Mathematical Modelling of Weld Phenomena (Cerjak, H., Easterling, K.E., eds.), p. 163. The Materials Society, London (1992)
Bhadeshia, H.K.D.H.: Bainite in Steels. Institute of Materials, London (1992)
Watt, D., Coon, L., Bibby, M., Goldak, J., Henwood, C.: An algorithm for modeling of micro structural development in weld heat affected zones (Part A) reaction kinetics. Acta Metall. 36, 3029–3035 (1988)
Henwood, C., Bibby, M., Goldak, J., Watt, D.: Coupled transient heat transfer—microstructure weld computation (Part B). Acta Metall. 36, 3037–3046 (1988)
Shen, Y., Radhakrishnan, B., Thompson, R.G.: International Trends in Welding Science and Technology (David, S.A., Vitek, J.M. eds.), p. 259. ASM International, Materials Park, OH (1993)
Bhadeshia, H.K.D.H., Svensson, L.E.: Mathematical Modeling of Weld Phenomena (Cerjak, H., Easterling, K.E. eds.), p. 109. The Materials Society, London (1992)
Bhadeshia, H.K.D.H.: Recent Trends in Welding Science and Technology (David, S.A., Vitek, J.M. eds.), p. 189. ASM International, Materials Park, OH (1990)
Ghosh, P.K., Gupta, P.C.: Influence of pulsed current MIG welding on the characteristics of Al–Zn–Mg alloy weldments. Trans. Indian Inst. Met. 44(4), 317–326 (1991)
Ghosh, P.K., Sharma, Vijay: Chemical composition and microstructure in pulsed MIG welded Al–Zn–Mg alloy weldments. Mater. Trans. JIM 32(2), 145–150 (1991)
Ghosh, P.K., Gupta, P.C., Somani, R.: Influence of pulse parameters on the porosity formation in pulsed MIG weld deposit of aluminium alloy. Int. J. Joining Mater. 3(2), 49–54 (1991)
Johnson, P.G., Szekely, J., Madigan, R.B., Quinn, T.P.: Power characteristics in GMAW: experimental and numerical investigations. Weld. J. 74(3), 93–102 (1995)
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
Copyright information
© 2017 Springer Nature Singapore Pte Ltd.
About this chapter
Cite this chapter
Ghosh, P.K. (2017). Introduction to Gas Metal Arc Welding Process. In: Pulse Current Gas Metal Arc Welding. Materials Forming, Machining and Tribology. Springer, Singapore. https://doi.org/10.1007/978-981-10-3557-9_1
Download citation
DOI: https://doi.org/10.1007/978-981-10-3557-9_1
Published:
Publisher Name: Springer, Singapore
Print ISBN: 978-981-10-3556-2
Online ISBN: 978-981-10-3557-9
eBook Packages: EngineeringEngineering (R0)