Gas Metal Arc Welding (GMAW) 

1. Introduction
In this lab, you will examine the effects of shielding gas and the different filler metal transfer modes in
Gas Metal Arc Welding process. In addition, you will also compare the Gas Metal Arc Welding
(GMAW) to Flux Cored Arc Welding (FCAW) and Metal Cored Arc Welding (MCAW) processes
when welding on mill scale steel plates.

2. Equipments and Materials

 Miller PipeWorx welding power supply.
 ESAB Mig 4002c welding power supply.
 0.035" ER70S-6 GMAW electrode.
 0.045" E71T-1 FCAW electrode.
 0.045" E70C-6 MCAW electrode.
 100% Argon shielding gas at 30 cfh flow rate.
 83% Argon + 17% CO2 shielding gas at 30 cfh flow rate.

3. Experimental Procedure
Effects of Shielding Gas

 With the 83% Argon + 17% CO2 shielding gas at 30 cfh flow rate, produce several welds on
steel plate. The wire feed speed (WFS) should be set at 300 ipm and voltage should be 25 V.
 Switch to Argon shielding gas and repeat the above step.
 Using 83% Argon + 17% CO2 shielding gas at 30 cfh flow rate and a steel plate, produce a long
weld bead. During welding, gradually decrease the flow rate to zero.

Results and Discussion: Observe the differences between the welds produced with different shielding
gases. What happens to the weld bead when the shielding gas is reduced?

Filler Metal Transfer Modes

 Set the WFS to 400 ipm and the voltage to 20 V.

 Leaving the WFS at 400 ipm, increase the voltage in 0.5V increments and make note of the
sound during welding, the spatters, the size and frequency of droplets transferred across the
welding arc. Maintain the welding gun at the same distance from the surface of the plate.

Results and Discussion: What happens to the filler metal transferred across the welding arc as the
welding voltage is increased?

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GMAW vs. FCAW vs. MCAW

 Using the spray transfer mode of GMAW process, make a bead-on-plate weld on a steel plate
with mill scale removed. Make note of weld quality and bead contour. Repeat welding on mill
scale steel plate.
 Using the FCAW process, produce a bead-on-plate on mill scale steel plate; the WFS is
approximately 400 ipm and the voltage is 26 V.
 Using the MCAW process, repeat the above step with WFS of 400 ipm and 26.5 Volts.

Results and Discussion: Based on the surface condition of a steel plate, which process should be used?

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