AUS C56 89 MM 0784265 000230 T mm Ee eke) Re eae Recommended Practices for Gas Metal Arc Welding 7 We es ty PUMA eC Ve$a AUS C5-b 89 MM 0784265 OO02L3) 1 mm Keywords — Gas metal are welding, joint ANSI/AWS C5.6-89 design, are spot welding, safety, ‘An American National Standard raining e Approved by ‘American National Standards Institute August 16, 1989 Recommended Practices for Gas Metal Arc Welding Prepared by AWS Committee on Are Welding and Cutting Under the Direction of AWS Technical Activities Committce e Anprove by AWS Board of Directors Abstract This standard is a recommended practice on the gas metal arc welding (GMAW) process. This document presents the basic concepts of this process and should enable the reader to obtain a fundamental understand= ing of this process and its variations, such as short circuit, spray, and pulsc modes of metal transfer. It provides the specific technical data which will act as a guide in establishing optimum operation of the process. American Welding Society ‘580 N.W. LeJeune Road, P.O. Box 351040, Miami, Florida $3135 Copia by the Ameian Nelng Society Satu 05 135401 1997AUS C5-b 89 MM O7842L5 OOOZL32 3 mm Statement on Use of AWS Standards Al standards (codes, specifications, recommended practices, methods, classifcations, and guides) of the American ‘Welding Society are voluntary consensus standards that have been developed in accordance with the rules of the American National Standards lstitute, When AWS standards ae either incorporated in, or made part of, documents that are included in, federal or state laws and regulations, or the regulations of other governmental bodies, their provisions carry the full legal authority of the statute. In such cases, any changes in those AWS standards must be approved by the governmental body having statutory jurisdiction before they ean become a part of those laws and regulations In all cases, these standatds cary the full egal authority of the contactor other document that invokes AWS standards. Where this contractual relationship exist, changes in or deviations from requirements of an AWS standard must be by agreement between the contracting parties. International Standard Book Number: 087171-201-2 American Welding Society, 580 N.W, LeJeune Road, P.O. Box 351040, Miami, Florida 33135 © 1989 by American Welding Society. All rights reserved Printed in the United States of America Note: The primary purpose of AWS isto serve and benefit its members. To this end, AWS provides a forum for the exchange, consideration, and discussion of ideas and proposals that are relevant to the welding industry and the ‘consensus of which forms the basis for these standards. By providingsuch a forum, AWS does not assume any duties to ‘which a user ofthese standards may be required to adhere. By publishing this standard, the American Welding Society does not insure anyone using the information it contains against any lability arising from that use. Publication of a standard by the American Wolding Society does not carry witht any right to make, use, orsell any patented items, Users ‘of the information in this standard should make an independent investigation of the validity ofthat information for their particular use and the patent status of any item referred to herein, “This standard i subject to revision at any time by the AWS Are Welding and Cutting Committe. It must be reviewed every five years and fot revised, it must be either eapproved or withdrawn. Comments (recommendations, additions, ordeletions) and any pertinent data that may be of sein improving thisstandard ae requested and should be addressed to AWS Headquarters, Such comments will recive careful considerations by the AWS Are Welding and Cutting Committe, ad the author ofthe comments wil be informed ofthe committe response tothe comments. Guests are Invited to attend all meetings ofthe AWS Are Welding and Cutting Commitice to express their comments verbally. Procedures for appeal ofan adverse decision conceraing all such comments are provided in the Rules of Operation of. the Technical Activities Commitee, A copy ofthese Rules can be obtained from the American Welding Society, 850 NW, Leleune Road, PO, Box 351040, Miami, Florida 33135, Copia by the Ameian Nelng Society Satu 05 135401 1997SUES VTeenrensmrameeesseer seed AUS CS.b 89 MM O7842L5 0002633 5 mm Personnel AWS Committee on Are Welding and Cutting E.R. Bohnart, Chairman JAR. Hannaks, Ist V. Chairman BLL. Shultz, 2nd V. Chairman W.A. Dierschow, Secretary D.R. Amos WL, Ballis KE, Banks RL. Bonnett L.A. Colarossi*® JR. Condra NA. Freytag RH. Frost RI. Hemzacek* GK. Hicken JE, Hinkel DB. Holliday EG. Northard** NE. Larson E.R. Pierre LJ. Privoznik. IS. Sayre LR. Soisson M.D. Stepath* EP Vilkas GK, Willecke** Miller Electric Mig, Company Midmark Corporation Taylor-Winfield Corporation American Welding Society Westinghouse Turbine Plant Columbia Gas Distribution Company ‘Teledyne Mekay ‘Thermal Dynamics Corporati Consultant E.l, DuPont de Nemours & Company ‘The Budd Company Colorado School of Mines Argonne National Laboratory Sandia National Laboratory Lincoln Electric Company Westinghouse Electric Corporation “Tennessee Valley Authority Union Carbide Corporation Liquid Air Corporation ‘Westinghouse Electric Corporation Consultant Arcair Company Arcair Company Astro Are Company ler Electric Mfg. Company ‘Subcommittee on Gas Metal Are Welding WL, Ballis, Chairman ER, Bohnart D.A. Fink NA, Freytag EH, Gray L. Helleman DB. Holliday GR. Rothehild* WG. Woolery Copy bythe Aretan Weng Sock he Sa ds 3540" 357 Columbia Gas Distribution Company Miller Electric Mfg. Company Lincoln Electric Company The Budd Company U,S. Nuclear Regulatory Commission Cincinnati Milacron Westinghouse Blectric Corporation Consultant Illinois Power Company“AUS CS-b 89 MM 0764265 OOD2b34 7 ml Foreword (This Foreword is not a part of ANSI/AWS C5.6-89, Recommended Practices for Gas Metal Arc Welding, but is included for information purposes only.) Gas metal arc welding (GMAW) was introduced as a practical fabricating process approximately thirty- eight years ago. In the past ten years, advances have been made in the development of techniques for ‘automatic applications. GMAW applications should continue to expand as fabricators become more familiar with the fundamentals, techniques, and advantages of this welding process. GMAW welding data was gathered in the late 1970's to yield an authoritative source of sound technical practices for gas metal are welding. Accordingly, the AWS Committee on Are Welding and Cutting prepared. this recommended practice for gas metal arc welding and published it in 1979. The 1989 edition is the first revision of the 1979 document. ‘The Committee has developed these guidelines in the hope that they will lead to further development of the gas metal arc process. Comments on this publication will be most welcome. They should be addressed to: Secretary, AWS Are Welding and Cutting Committee, American Welding Society, 550 N.W. LeJeune Road, P.O. Box 351040, Miami, Florida 33135, Copia by the Ameian Nelng Society Satu 05 135401 1997AUS CS-b 55 M™ 0784255 OOO2L35 9 mm Table of Contents Personnel . Foreword... List of Tables List of Figures 1. Seope ... 2, Fundamentals ......- 2.1 Principals of Operation. 2.2 Characteristics 2.3 Variations... Su Edelnenl ener ree eee 3.1 Introduetion 1... 3.2 Semiautomatic Welding Equipment . 3.3 Automatic Welding Equipment . 4.1 Shielding Gas 4.2 Electrodes . 4°3 Selection of Process Variables 4.4 Welding Variables. . e 4. Process Requirements and Application 5. General Joint Design .....sseecveeeetevessseeeeeee 2s 6. Spot Welding .. go0000 2s 6.1 Equipment Operation... 3B 6.2 Effect of Provess Variables on Weld Characteristics «11.1. .....0 5 3 6.3 Joint Design ; : Fi 5 33 6.44 Tension-Shear Test ....... oe a 7. Inapection and Weld Qualiy a TA Introduction... a) 7.2 Potential Problems . .. a 1.3 Weld Discontinuities . 44 8. Training +...60000 49 8.1 Introductory Training Program on Steel 0 8.2 Welding Nonferrous Metals 5 50 8.3 GMAW Course for Stee! Pipe. a Pee eee st 8.4 GMAW Equipment Maintenance and Trouble-Shooting Course SI St Copia by the Ameian Nelng Society Satu 05 135401 1997“AUS C5-b 81 mM O7BU2bS GOALIE O Mm 9% Qualification. 9.1 Introduction 92. General. 9.3. Prooedure 94 Variables , 9S ‘Types of Tests « 10, Safe Practices ..... 106 Noise .....- 10.7 Other Factors Copia by the Ameian Nelng Society Satu 05 135401 1997re AUS CS-b 89 MM O784265 0002637 2 mm List of Tables Table 1 ~ Typical Currents (Short Circuit) for Metal Transfer in the Short Cieui (Power Source-Static Characteristics)... 2— Shielding Gases and Gas Mixtures for GMAW . 3 — Selection of Gases for GMAW with Spray Transfer 4— Selection of Gases for GMAW with Short Cireuiting Transfer ..- 5 —~ Recommended Filler Metals for GMAW 6 — How Changes in Welding Variables Affect Weld... 7 ~ Suength Equivalents (Effective Throat Depth) by Process for Fillet Welds... 8 — GMAW Spot Welding of Plain Carbon Steel in the Flat Position CO; Shielding Gas 3/16 in, (4.8 mm) Diameter Nugget . — GMAW Spot Welding of Plain Carbon Steel in the 1/4 in, (64 mm) Diameter Nugget ee 10 — GMAW Spot and Plug Welds on Aluminum Argon Shielding Gas ~ 1/16 in, (1.6 mm) Diameter Electrode . Ben 11 — Summary of Operating Conditions for GMAW Spot Welding of Ver ‘AZ31B (Magnesium) sheet with AZ6IA Electrode . : 12 — GMAW Spot Welding of Stainless Stee to Plain Carbon Stee! in the Flat Position lat Posi tion co, Shielding ‘Gas Copia by the Ameian Nelng Society Satu 05 135401 1997AUS C5-b 69 MM 0764265 OOO2L38 4 mm List of Figures Figure Page No. 1 Basic GMAW Equipment ....e.essse+ Ee 2—Illusteation of Pinch Effect ...- 3 — Melting Rates of Gas Metal Arc El : ‘4 — Variation in Volume and Transfer Rate of Droplets with Welding Current 5 — Weld Metal Transfer Characteristics ...... 6 — Oscilograms and Sketches of Short Cireuiting Are Metal Transfer « 7 Time/ Ampere Curve for Pulsed Current os 8 — Schematic of Typical Flectrogas Equipment in Weld Area... 9 — Semiautomatic Gas Metal Are Welding Installation (Water Cooling of the Torch is Snciona 10 — Machine Gas Metal Are Welding Installation. 5 11 — Static Volt-Ampere Characteristics. 12— Automatic Regolation of Are Length in the GMAW Process with @ Conventional Power Supply +++ +++ : 13 — Caleulation of the Slope for a Power Source 14 — Musration of Pinch Effect During Short Cireuiting Transfer 15 — Effect of Changing Slope... : 16— Change in Rate of Current Rise Duc to Added Inductance 17 — Bead Cross Section and Depth of Fusion (Penetration) Patterns with Various Shielding Gases .. 18 — Relative Eft of ©, Vero CO, Aditons to the Argon Shield 19 — Flectrode Extension - = 20— Typical Melting Rates for Plain Carbon Steel... 21 — Typical Welding Currents Versus Wire Feed Speeds for Carbon Steel Electrodes... 22 — ‘Typical Melting Rates for Aluminum Electrodes . a 23 — Welding Currents Verous Wire Feed Speed for ER4043 Aluminum Electrodes... 24 — Welding Currents Versus Wire Feed Speed for ERS356 Aluminum Electrodes... 25 — Typical Melting Rates for 300 Series Stainless Steet Electrodes 26 — Typical Welding Currents Versus Wire Feed Speeds for 300 Series Stanles Stel Blecrodes 21 Typical Melting Rates for ECu Copper Electrodes .. Fi 28 — Welding Currents Versus Wire Feed Speed for ECu Copper Flectrodes 29 — Typical Melting Rates for ECuSi-A Copper Electrodes ......- : 30 — Welding Currents Versus Wite Feed Speed for ECuSi-A Copper Electrodes.....+.++ 31 — Typical Currents Versus Wire Feed Speed for Magnesium Electrodes ... 32.— Optimum Short Circuit Transfer for Plain Carbon Steel Electrodes... 33 — Optimum Short Circuit Transfer for Carbon Stee! Fleetrodes. 34 —Tipical Wed Joint Design fr GMAW (Ste) 35 — Fillet Weld — Bifective Throats . 36 — Types of Joints for GMAW Spot Welding... +... 37 — Tension — Shear Test Specimen Dimensions 38 — Undercutting at the Toe of the Weld ...+.+. +++ 39 — Porosity Due to Inadequate Shielding Gas Coverage 40 — Porosity Due to Bxcessive Voltage v..+.+s+s0++++ ‘ ‘41 — Incomplete Fusion De to Narrow Groove Preparation (5083 Aluminum Plate and ERSI83 Filler Metal)... : 42.— Incomplete Root Penetration Due to Inadequate Welding Current 43 — Weld Metal Cracking Due to Excessive Depth-to-Width Ratio... vi Copia by the Ameian Nelng Society Satu 05 135401 1997need AUS C5-b 89 MM O7B4265 0002639 b mm 44 — Weld Metal Cracking in Crater at End of Weld... 45 — Incomplete Fusion Due to Exeesive Travel Speed 46 — Weld Bead Waviness e 47 — Sagging of Weld Bead Duc to Position of Welding» 48 — Overlap of Weld Bead Due to Incorrect Voltage 62 Honing of Weld Mea DustoEacsie ae Spel. 50 — Example of Workmanship Samples - $1 — Example of Workmanship Sample. 52 — Workinanship Specimens ...+++.0.e- a 4533 — Penetration of Piller Weld Break Test Specimen s..s0..s0.. '54-— Methods for Facilitating Fillet Weld Fracture, . 55 — Longitudinal Filet Weld Shearing Specimen After Welding $36 — Transverse Filet Weld Shearing Specimen . 57 — Longitudinal Filet Weld Specimen After Machining 458 — Fillet Weld-Soundness Test Specimen ......+« 539 — Reduced-Section Tension Specimen (Pits)... {60 — Reduced-Section Tension Specimen (Pipe) 61 — Face- and Root-Bend Specimen (Plate). Copia by the Ameian Nelng Society Satu 05 135401 1997— AUS CS-6 89 MM 0784265 O002b40 2 mm Recommended Practices for Gas Metal Arc Welding Note: The U.S. customary units are primary in this publication. However, the approximate equivalent SI values are listed in text and tables to familiarize the reader with the SI system of metric units. 1, Scope It is intended in this publication to present the basic concepts of the gas metal arc welding (GMAW) process that will enable the reader to ob- tain a fundamental understanding of the process and its variations." This knowledge, combined with basic information about other weiding processes, should be helpful to the readcr in the selection of the best welding process for metals to be joined. In ad- dition, the reader will find specific technical data which will bea guide in establishing optimum oper ation of this process. Historically, the GMAW process was developed and made commercially available in 1948, although the basic concept was actually introduced in the 1920's, In its early commercial applications, the process was used to weld aluminum with an inert shielding gas, giving rise to the term MIG (metal in- ert gas) which is still in common usage when refer- ring to the process. As time went on, variations were added to the process, among which was the use of active shielding gases, particularly COs, for welding certain ferrous materials. This eventually led to the |. Gas metal are welding is defined as. an are welding pro- «ess that produces coalescenes of metals by hesting them with an arc between @ continuous filler metal eleetrode and the workpieces. Shielding is obtained entvely fo an externally supplied gas. formally accepted AWS term of gas metal are weld- ing (GMAW) for the process. Further developments to the process included the following: the short circuiting mode of metal trans- fer (GMAW-S),a lower heat energy variation of the process that permits welding in all positions and also on shect metal thicknesses; a method using ‘molding shoes to confine the molten weld metal for vertical welding electrogas welding (EGW); and a ‘method of controlled pulsating current (GMAW-P) to provide a uniform spray droplet metal transfer from the electrode at lower average current levels. ‘The GMAW process uses either semiautomatic, machine, or automatic equipment and is princi pally applied in high production welding, Most ‘metals can be welded with this process and may be welded in all positions with the low energy variae tions of the process. GMAW is an economical pro- cess that requires little or no cleaning of the weld metal. Warpage and metal finishing are minimal, Each of the variations of GMAW provides spo- cific advantages, and standard process equipment is normally designed to permit the use of several of these variations. However, some equipment is de- signed for one specific mode only. Other variations, such as pulsed current or other processes such as clectrogas, require essentially special units which ‘are unique for these variations. The Committee has prepared these recom- mended practices as guidelines with the hope that they will serve as an incentive for industry to further develop the GMAW process. The Committee iscon- tinuing its activities to provide data for additional materials, designs, and equipment, and these rec- ‘ommended practices will be revised as new inlor- ‘mation becomes available, Copia by the Ameian Nelng Society Satu 05 135401 19972. Fundamentals 2.1 Principles of Operation. GMAW is an arc weld- ing process which incorporates the automatic feed- ing of a continuous, consumable electrode that is shielded by an externally supplied gas. Since the equipment provides for automatic control of the are, the only manual controls required by the welder for semiautomatic operation are the travel speed, ‘and gun positioning and guidance. Process control and function are achieved through these the basic elements of equipment (see Figure 1). a) Gun (2) Electrode Feed unit @) Power Source ‘The gun guides the consumable electrode and conduets the electrical current and shielding gas to the workpicee. The electrode feed unit and power source are used ina system that provides automatic regulation of the arc length. The basic combination used to produce this regulation consists of a con- stant voltage power source (characteristically pro- viding an essentially flat volt-ampere curve) in conjunction with a constant speed electrode feed unit, The are length self-regulation produced by the constant voltage power source, constant speed electrode feed unit combination is described in detail in 3.2.5, Some GMAW equipment, however, uses a constant current power source (characteristi- SHIELOING GAS: REGULATOR ELECTRODE FEED UN, SHIELOING GAS: SUPPLY POWER SOURCE WORKPIECE Figure 1 - Basic GMAW Equipment Copia by the Ameian Nelng Society Satu 05 135401 1997 “AUS C5-b 89 mH 0784265 OGY] 4 mm cally providing a drooping volt-ampere curve) plus an are vollage-controlled electrode feed unit. With this constant current combination, arc voltage changes, caused by a change in the arc length, will initiate a response in the electrode feed unit to either increase or decrease the electrode feed speed to maintain the original arc length setting, In some applications, a constant current power source may bbe coupled ‘with a constant speed electrode feed unit, This combination will provide only a small gree of automatic self-regulation and can be quite demanding in technique and set-up for semi automatic welding, However, some users think this combination af- fords the range of control over the arc energy that is considered important in coping with the high ther mal conductivity of the aluminum base metal 24.4 The following are some advantages of GMAW when compared to SMAW: (1) Can be used in all positions with the low ‘energy modes (2) Virtually no slag to remove or trap in weld (3) Less welder training time than SMAW (4) No stub toss (5) Adaptable to semiautomatic, machine and automatic welding (6) Low hydrogen process (7) Faster welding speeds than that used for SMAW 2.1.2 Thesfollowing are some limitations of GMAW when compared to SMAW: (1) The related welding equipment is more com- plex, more costly, and less portable. (2) The shielding gas must be protected from strong winds and air drafts. (3) The cooling rates of the completed weld are higher than slag producing processes. (4) The welding gun is larger than SMAW elec- trodes, making it difficult to weld hard-to-reach joint locations. (5) The short circuiting welding arc is smaller than the arc produced with the SMAW process, ‘Therefore, the possibility of incomplete fusion ex- {sts on thicker weldments due to less heat input and because of arc outages. (6) The base metal must be cleaned before weld- ing while SMAW can tolerate some contamination. 2.2 Characteristics. The characteristics of GMAW are best described by the three basic modes of metal transfer which may occur with the process: axialSneed AUS C5.6 69 MM 0784265 0002642 b mm spray transfer, globular transfer, and short circuiting transfer. Axial spray and globular transfer are associ- ated basically with relatively high arc energy. With the occasional exception of the spray mode in very + small diameter electrodes, both axial spray and glob- ular transfer are normally limited to the lat and hori- zontal welding positions with base metal thickness of not ess than 1/8 in, (3.2 mm), Pulsed spray transfer, {in which the average energy level is reduced, is an- other exception (see 2.3.1). Short circuiting transfer isa relatively low energy process generally limited to base metal thicknesses not more than 1/8 in,, but is used in all welding positions. ‘The physics of weld metal transfer are well under- stood. A combination of forces is responsible for de- taching the molten metal from the electrode and propelling it across the arc to the base metal. Two of these forces, gravity and “pinch effect,” may becon- sidered in a simple description of the mechanism of transfer and its three basic modes. Pinch effect is the momentary necking of the liq- drop from the current carrying electrode that ‘occurs as a result of the electromagnetic effects of the current (Figure 2). I is the key to axial spray transfer (See 3.2.6.2). In any conductor, the pinch effect force is proportional to the square of the cur rent flowing through it; ie. if the current is dou- bled, the pinch force will be four times as large. This pinch effect can be made large enough to cause the electrode to “neck down” and finally to separate. ‘The molten drop at the end of an electrode is easily, pinched off at normal welding currents. Globular transfer is characterized by the predominant effect of the force of gravity. 2.2.1 Axial Spray Transfer (Gas Shield with a Minimum of 90 Percent Argon). In this mode, ‘metal transfer across the are is in the form of drop- lets of size equal to or less than the electrode diam- ter. The droplets are directed axially in a straight line from the electrode to the weld pool. The arc is very smooth and stable. ‘The axial spray transfer mode is established at a ‘minimum current level for any given electrode di- ameter (current density). This current level is gener- ally termed the transition current (see Figures 3 and 4), A well defined transition current exists only with gas shield containing a minimum of ninety percent ‘argon, At current levels below the transition cur rent, the drop size increases larger than the diame- ter of the electrode (see Figures 4 and S).The are characteristics are quite unstable in this operating range. Copia by the Ameian Nelng Society Satu 05 135401 1997 CURRENT (4) ELECTRODE pea? “¢—PINCH EFFECT FORCE, P Figure 2 - Illustration of Pinch Effect 2.2.2 Globular Transfer (Gas Shield with CO; or Helium). In this mode, metal transfer across the are is in the form of irregular globules randomly di- rected across the arc in irregular fashion (see Figure 5), resulting in a considerable amount of spatter. Spatter is minimized when using CO» shield by ad- jjusting the welding conditions so that the tip of the ‘electrode is below the surface of the weld pool and ‘within a cavity generated by the foree of the arc. The CO; arc is generally unstable and characterized bya crackling sound. It results in a weld bead surface ‘that is rough in appearance (cipple effect) in com- parison to. bead obtained with axial spray transfer. Since most of the arc energy is directed downward and below the surface of the weld pool, the weld bead cross section exhibits very deep fusion with less wetting at the weld bead extremities than that ‘obtained in the axial spray transfer mode. Relative stability of the CO; arc can be established at higher ‘current levels using a buried arc; ie., wire melts be- low surface of base metal. ‘When helium-rich gas mixtures are used, a broader weld bead is produced with a depth of fu- sion similac to that of argon, but with a more desir- able cross section.AUS C5S-6 89 MM O784245 OOO2L43 5 mm 4 ALUMI wine _ PosmTve ELECTRODE otbin, ARGON GAS x0 fom) 1000 as 2 0.020% 2 5 {08 mm 5 E00 iE = foa20'n oa g (08 3 i Sane) B Foot | 2 : * 047 in # 2 ot ‘zm | 92 oainy 8 ET enor \ soma a ie 5 i se 5 wo mo ato atl ccunaeNt, A (a) ALUMINUM ELECTRODE DCEP ‘ARGON SHIELDED GAS. 0.020n. 0.025 in {0 rom) (07 wn 1200 wren! Sa poe 2 ‘0.039 in. 2 = {0.8 mm) 5 3 /, “4 3 (09mm E # fossin, |B = ‘C092 in| S 200 {1.6 min) ] 3 ‘CURRENT 0 0 00S ‘CURRENT, A (@) STEEL ELECTRODE DoEP ARGON - 2% ARGON SHIELONG GAS Figure 3 - Melting Rates of Gas Metal Arc Electrodes 2.2.3 Short Circuiting Transfer (GMAW-S). In the short cireuiting, low energy mode, all metal transfer occurs when the electrode is in contact with the weld pool. In this mode of metal transfer, the power source characteristics control the relation- ship between the intermittent establishment of an are and the short circuiting of the electrode to the work (see Figure 6). Since the heat input is low, the depth of fusion is very shallow, thus, care must be exercised in selecting a procedure and a technique to assure complete fusion when welding thick base ‘metal. However, these characteristics permit weld- ing in all positions. Short circuiting transfer is par- ticularly adaptable to welding sheet metal. 2.3 Variations 2.3.4 Pulsed Current ‘Transfer (GMAW-P). This is a GMAW process variation capable of having 00d weld pool control ata higher energy level than with short circuit transfer. In this variation, the power souree provides two output levels: « steady background level, too low in magnitude to produce any transfer, but able to maintain an arc; and a pulsed high output level which causes melting of Copia by the Ameian Nelng Society Satu 05 135401 1997 1/4 in, (6.4 mm) ‘ARC VOLTAGE 24 VOLTS 29 VOLTS 24 VOLTS: ARC CURRENT 260 AMPS: 220 AMPS: <250 AMPS: ELECTRODE WIRE FEED 250 IPM (108 mm/s) 250 IPM (106 mm/s) 260 IPM (108 mm/s) INSTANTANEOUS MELTING RATE: 260 IPM (108 mm/s) 220 IPM (93 mm/s) 250 IPM (106 mm/s) Figure 12 - Automatic Regu lation of Arc Length in the GMAW Process with ‘a Conventional Power Supply e Copia by the Ameian Nelng Society Satu 05 135401 1997$$ AUS C5.6 85 MM 0784265 o00254 2 mm force) is a function of the slope of the volt-ampere characteristics of the power source, as shown in Fig- ure 15, Although the welding voltage and amperage of these two power sources arc identical, the short circuit current of curve A is less than that of curve B, Curve A has the steeper slope or a greater voltage drop per 100 amperes as compared to curve B; ie, the steeper the slope, the lower the short circuit cur- rent and pinch effect; the flatter the slope, the higher the short circuit current and pinch effect. In short circuiting welding, the amount of short circuit current is important since its resultant pinch effet determines the way a molten drop de- taches from the electrode. This in turn affects the are stability. When little or no slope is present in the power source circuit, the short cireuit current will rise to a very high level. At high currents, the pinch effect is also very high, and a violent parting of the molten drop takes place, acting as a fuse The excessive pinch effect will violently squeeze the metal aside and break the short circuit, pro- ducing spatter, When the short circuit current available from the power source is limited to low values by a steep slope, the electrode can carry the full current and the short circuit will not be broken. Under these conditions the electrode will either pile up on the workpices or freeze to the weld pool. When the short circuit current is at the correct value, the part- ing of the molten drop from the electrode is smooth with very little spatter. Typical short circuit currents open cincur VOLTAGE » 48 seLecTED OPERATING POINT (@ 28, 2004 VOLTAGE, v ‘CURRENT, A ev, vam | pv Ov ree SANaE a0 BoA ~ 100K Figure 13 - Calculation of the Slope for a Power Source Copia by the Ameian Nelng Society Satu 05 135401 1997 required for metal transfer with the best arc stabil are shown in Table 1. Many CV power sources are equipped for chang ing the slope of the volt-ampere curve. They may be stepped or continuously adjustable to provide the correct short circuit current for the application in- volved. Some havea fixed slope which has been pre- determined for a given condition of welding. 3.2.6.3 Inductance, When the load changes on 4 power soutee, the current takes a definite time to alain its new level. The circuit characteristic pri- marily responsible for this time lag is the induc~ tance, This power source variable is usually ‘measured in henrys. The effect of inductance is, illustrated by the curves plotted in Figure 16. Curve ‘Ashows a typical current-time curve. As the current rises from zero to a final value, some inductance is. ‘added. This curve is said to have a rate of current rise (commonly called response”), Curve B shows the path the current would have taken if there were no inductance in the circuit, ‘The maximum amount of pinch effect is deter- mined by the short circuit current level. As noted carlier, this current level is determined by the slope of the power source. The rate of increase of the pinch effect is controlled by the rate of increase of current rise, The rate of current rise is deter- mined by the inductance of the power source. If ‘CURRENT A) ELECTRODE Pant —= PINCH EFFECT FORCE, P juring Short Circuiting Transfercunve A [OPERATING POINT OUTAGE, V cuRve 8 ‘CURRENT, A Figure 15 ~ Effect of Changing Slope the pinch effect is applied rapidly, the molten drop will be violently squeezed off the electrode and cause spatter, Greater inductance will decrease the umber of short circuit metal transfers per second and increase the arc-on time. This increased atc- con time results in a flatter, smoother weld bead. The opposite is true when the inductance is de- creased In spray transfer welding, the addition of some inductance to the power source will produce a softer, more usable start without reducing the final amount of current available. Too much inductance will result in electrode stubbing on the start. Spaiter is held toa minimum when adequate cur- rent and correct rate of current rise exist. The power source adjustments required for minimum spatter conditions vary with the electrode material and size. Asa general rule, both the amount of short cir- cuit current and the amount of inductance needed for the ideal pinch effect are increased as the elec- trode diameter is increased. Power sources are available with fixed, stepped, or continuously adjustable inductance levels, | AUS C5eb 89 MM O784265 OOOZLSS 4 mm (CURVE 8 _NO INDUCTANCE ‘CURVE A - INDUCTANCE ADDED CURRENT. A TM, § Figure 16 - Change in Rate ‘of Current Rise Due to Added Inductance 3.3 Automatic Welding Equipment. This type of ‘welding equipment installation is effectively used when the work can be more easily brought to the welding station or when a great deal of welding must be done, Weld travel speed and weld quality can be greatly increased because arc travel is auto ‘matic and precisely controlled. Basically, all of the equipment is identical to that needed in a semiautomatic station except for the following changes (see Figure 10) (1) The welding gun is mounted directly under the electrode feed motor. The electrode conduit gun handle, and gun switch are not used. (2) The welding control is mounted separately from the electrode feed motor. The welding control may have additional controls, such as preweld and postweld gas and water flow, starting speed, crater fill, and burnback. Also, equipment such as the following is needed to provide automatic are or workpiece travel: (1) Side beam carriage with moter control (2) Positioner or manipulator (3) Robotic systems | Table 1 Typical Currents (Short Circuit) tor Metal Transfer in the Short Circulting Modo (Power Source ~ Static Characteristics) ‘Short Cireuit Electrode Diameter Current, Blectrode Material Ta om amperes (deep) Carbon steel 0.030 08 300 Carbon steel 0.035 09 320 0.030 08 us 0.035 09 195 Copia by the Ameian Nelng Society Satu 05 135401 1997AUS C5S-b 64 MM O?84265 OOZES b am The side beam carriage is mounted on a side beam which must be parallel (o the weld joint. The electrode feed motor, electrode spool, welding con- trol, and travel speed governor are usually mounted ‘on the side beam carriage. The carriage motor sup- plies movement of the carriage. The speed of travel is adjusted through connections to the governor. Other types of equipment can be used for auto- matic travel. These include beams, carriages mounted on tracks, and specially built positioners and fixtures, The welding control regulates travel to coincide with the weld start and stop. Automatic welding can also be accomplished by movement of the work under a fixed welding head; for example, by attaching to, and moving the work in a weld positioner. Robotic systems are being used more frequently today in high volume production applications. A robotic work cell isa basic subdivision of a flexible manufacturing system and consists of robot mani- pulator, a controller, apart positioner, a part fixture and a welding process equipment assembly. The ro- bot system is programmed to weld automatically along the paths of a joint which may have com- pound curvatures associated with it (ie., it must ‘operate in three dimensional space.) Recent devel- ‘opments with various sensors have indicated that adaptive controls to compensate for normal part or processing variations will be commonplace in the future, 4, Process Requirements and Applications In GMAW, by definition, coalescence of metals is produced by heating them with an are established between a continuous filler metal electrode and the work. The shielding gas and the consumable elec- trode are two essential requirements for this process. 4.1 Shielding Gas 4.1.1 General. Most metals exhibit a strong ten- dency to combine with oxygen (to form oxides) and to.a lesser extent with nitrogen (to form metal ni- tides). Oxygen will also react with carbon to form earbon monoxide and carbon dioxide gas. These ro- action products are all a source of weld deficiencies in the form of: fusion defects due to oxides loss of strength due to porosity, oxides, and nitrides; and weld metal embrittlement due to dissolved oxides and nitrides, Since the atmosphere is composed of approximately eighty percent nitrogen and twenty percent oxygen, these reaction products arc casily formed, The primary function of the shielding gas is to exclude the surrounding atmosphere from con- tact with the molten weld metal, ‘The shielding gas will also have a pronounced effect upon the following aspects of welding and the resultant weld: (1) Are characteristics (2) Mode of metal transfer 3) Depth of fusion and weld bead profile (4) Speed of welding (5) Undercutting tendency (6) Cleaning action 4.1.2 The Inert Shielding Gases-Argon and Helium. Argon and helium are inert gases. These gases and mixtures ofthe two are necessarily used in the welding of nonferrous metals and also widely used to weld stainless steel and low alloy steels. The following are basie differences between argon and helium: (1) Density ‘The density of argon is approximately 1.4 times that of air (heavier) while the density of helium is approximately 0.14 times that of air (lighter). The heavier the gas, the more effective iti at any given flow rate for shielding the arc and blanketing the weld area in flat position (downhand) welding, ‘Therefore, helium shielding requires approximately two or three times higher flow rates than argon shielding, in order to provide the same effective protection, Helium possesses a higher thermal conductivity than argon and also produces an are plasma in which the are energy is more uniformly dispersed. “Theargon are plasma is characterized by avery high energy inner eore and an outer mantle of lesser heat energy. This difference strongly affects the weld bead cross section, The helium are produces a deep, broad, parabolic weld bead, The argon arc produces a bead cross section most often characterized by @ papillary (nipple) type penetration pattern (see Fig- ure 17) ‘At any given wire feed speed, the voltage ofthe argon are will be noticeably less than that ofthe he- lium are. As result there will be less change in the voltage with respect to change in are length for the argon ate, and the are will tend to be more stable than the helium are, The argon are (including mix tures with s low as ninety pereent argon) will pro duce an axial spray transfer at current levels above Copia by the Ameian Nelng Society Satu 05 135401 1997AUS C5-6 89 MH O7842b5 O002bS7 8 mm the teansition current. The helium-shielded are pro- duces @ metal transfer of large droplets in the nor- ‘mal operating range, Therefore, the helium arc will produce a higher spatter level and poorer weld face appearance compared to the argon arc. The more readily ionized argon gas also facili tates are starting and will provide superior surface cleaning action when used with electrode positive. 4.1.3 Mixtures of Argon and Helium. Pure argon shielding is used in many applications for welding nonferrous metals, The use of pure helium is gener= ally restricted to more specialized areas because of its limited are stability. However, the desirable ‘weld bead cross section (deep, broad, and para- bolic) obtained with the helium are are quite often, the objective in using an argon-helium shielding gas mixture, The result is an improved weld bead cross section plus the desirable axial spray metal transfer characteristics of argon (see Figure 17). In short circuiting transfer, argon helium mix- tures of from sixty to ninety percent helium areused to obtain higher heat input into the base metal for Detter fusion characteristics. For some metals, such as stainless and low alloy steels, helium additions are chosen to obtain higher heat input, instead of CO; additions, because helium will not produce ‘weld metal reactions that could adversely affect the mechanical properties of the deposit. 4.1.4 Oxygen and CO; Additions to Argon and He- ium, Pure argon and, to some extent, helium pro- duce excellent results in welding nonferrous metals. Vie However, these shielding gases in the pure form do not produce the most satisfactory operational char- acteristics in welding ferrous metals. The arc tends to be erratic, accompanied by spatter with helium shielding, and shows a marked tendency to produce undercutting with pure argon shielding. Additions to argon of from one to five percent oxygen or from three to ten percent CO2 (and up to twenty five per= ‘cent CO2) produce a very noticeable improvement, The optimum amount of oxygen or CO: to be added to the inert gas is a function of the surface condition (mill scale) of the base metal, the joint geometry, welding position or technique, and the ‘base metal composition. Generally, three percent ‘oxygen oF nine percent COr is considered a good ‘compromise to caver a broad range of these vati- ables. Carbon dioxide additions to argon also tend to enhance the weld bead by producing a more readily defined pear-shaped cross section (see Figure 18), 4.1.5 Carbon Dioxide. Carbon dioxide (CO) is a reactive gas widely used in its pure form for the gas ‘metal are welding of carbon and Jow alloy steels. It is the only reactive gas suitable for use alone as a shield in the GMAW process. Higher welding speed, ‘reater joint penetration, and lower cost are general characicristics which have encouraged extensive use of CO; welding gas. ‘With a COs shield, metal transfer is either of the short cireuiting or globular mode. Axial spray trans- fer is a characteristic of the argon shield and cannot be achieved with a CO; shield, The globular type ARGON ‘ARGON -HELIUMA Heuun co: Figure 17 - Bead Cross Section and Depth of Fusion (Penetration) Patterns with Various Shielding Gases Copia by the Ameian Nelng Society Satu 05 135401 1997$n AUS C5.b 89 MM O7842L5 OOO2b58 T mm ‘transfer arc is harsh and produces a rather high level of spatter. This requires that the welding conditions be set with relatively low voltage to provide a very short buried arc (the tip ofthe electrode is actually below the surface of the work), in order to minimize spatter, In overall comparison to the argon-tich shielded aro, the CO;-shielded are produces a weld bead of excellent penetration with a rougher surface profile and much less wetting action at the extremity of the weld bead due to the buried arc. Very sound weld deposits are achieved, but mechanical properties may be adversely affected duc to the oxidizing na- ture of the are. 4.1.6 Shielding Gas Selection. A summary of typical usage for the various shielding gases based upon the metal being welded is shown in Tables 2, 3, and 4, 4.2 Electrodes 4.2.1 General. In the engineering of weldments, filler metals are selected to produce a weld deposit with these basic objectives: (1) A deposit closely matching the mechanical properties and physical characteristics of the base ‘metal Q) A sound weld deposit, free of discontinuities Note the first objective. A weld deposit, even one of composition identical to the base metal, will pos- sess unique metallurgical characteristics. There- fore, the first objective of the weldment design is to produce a weld deposit composition having desired properties equal to or better than those of the base ‘metal. The second objective is generally achieved through use of a filler metal electrode that was for- mulated to produce a relatively defect-free deposit, 4.2.2. Composition. The basic filler metal compo- sition is designed to be compatible with one or more of the following base metal characteristi: () Chemistry (2) Strength, 3) Duetility 4) Toughness Alternate or additional consideration may be given to other properties such as corrosion, heat treatment response, wear resistance, color match, ete. All of these considerations, however, are sec ‘ondary to the metallurgical compatability of the base metal to the filler metal. ‘American Welding Society specifications have been established for filler metals in common usage, ‘Table 5 provides a basic guide to some typical base- metal to filler-metal combinations along with the applicable AWS filler metal specification. Other filler metal compositions for special applications, such as for high-strength steels, are available 4.2.3 Formulation. ‘The electrode must also meet certain demands of the process regarding arc stabil ity, metal transfer behavior, and solidification char- acteristics. Deoxidizers or other scavenging agents arealways added to compensate for base metal reac- tions with oxygen, nitrogen, and hydrogen from the surrounding atmosphere or the base metal, The de- oxidizers most frequently used in steel are silicon ‘and manganese, Some steel electrodes may also use aluminum for additional deoxidation, as well as ti- tanium and zirconium for denitriding, Nickel alloy electrodes generally use titanium and zirconium for deoxidation, and copper alloys will use titanium and silicon or phosphorus for the same purpose, 43 Selection of Process Variables. Many process variables must be considered for complete applica- "ARGON-Oe "ARGON=COe Figure 18 - Relative Effect of O2 Versus CO2 Additions to the Argon Shield Copia by the Ameian Nelng Society Satu 05 135401 199720 tion of GMAW. These variables are found in the fol- lowing three principal areas: (1) Equipment selection (Q) Mode of metal transfer and shielding gas @) Electrode selection ‘These three areas are very much interrelated, 4.3.1 Equipment Selection, A variety of options and basic equipment designs is available for equip- ‘ment selection, Equipment should be selected that will fit the product application and the weldment design, since the equipment must possess the eapac- ity to do the job. Range of power output, range of, open circuit voltage, static and dynamic character- istics, wire feed speed range, ete., must correspond to the weldment design (in particular, weld size) and the electrode size selected. Also to be consid- ‘ered are the accessories required for the selected mode of metal transfer and any other special re- quirements ‘When new equipment is to be purchased, some consideration should be given to the versatility of the equipment and to standardization. Selection of equipment for single-purpose or high volume pro- duction ean generally be based upon the require- ‘ments of that particular application only. However, fa multitude of jobs is to be performed (as in a job shop operation), many of which may be unknown at AUS C5-b 89 MM 0784265 COO2ES9 1 mm the time of selection, versatility is very important. Other equipment already in use at the facility should be considered. Standardizing certain com- ponents and complementing existing equipment ‘will minimize inventory requirements and provide maximum efficiency of overall operation. 4.3.2 Mode of Metal ‘Transfer and Shielding Gas. ‘Thecharacteristis of the mode of metal transfer are very important in analysis of the process applica- tion, Characteristics such as weld bead cross seo- tion, reinforcement shape, spatter, etc. are relevant to the weldment design, The following major con- siderations reflect the importance of these charac- teristics. 4 Design and Service Performance, Product design, as well as spocific weld joint design, requires consideration of root penetration and reinforeement ‘ross sections. Both static and dynamic service perfor= manee requirements may dictate the need for addi- ‘tional strength (in the form of penetration) or minimal stress concentration (good wetting characteristics) ‘The shielding gas selection is very important in deter- mining these basic characteristics. 4.3.2.2 Process Control. Metal thickness may require using the pulse current or low energy short Table 2 Shielding Gases and Gas Mixtures for GMAW ‘Chemical Shielding Gas Behavior ‘Typical Application ‘Argon’ Inert Virtually all metals except secs. Aluminum, magnesium, and copper alloys for greater heat input and Helium Inert to minimize porosity ‘Aluminum, magnesium, and copper slloys for greater heat input and Ar-+20-80% He nest to minimize porosity (better arc action than 100% helium), | Nitrogen Greater heat input on eopper (Europe) Greater heat input on copper (Europe) better are action than 100 A+25.30% Ns percent nitrogen, Art 1.2% 0 Slightly oxidizing Stainless and alloy steels; some deoxidized copper alloys ‘Ar + 35% Os Oxidizing Carbon and some low-lloy steels. CO: Oxidizing Carbon and some low-alloy steels. Ar-+ 20.50% COs Oxidizing Various steels, chiefly short circuting mode, Ar + 10% CO; + 5% 0, Oxidizing Various stels (Europe). COs + 20% 03 Oxidizing ‘Various steels (Japan). 90% He + 7.5% Ar 2.5% CO, Slightly oxidizing Stainless steels for good corrosion resistance, short circuiting mode, 60 to 70% He + 25 to 3506 Art 4 to SCO, Oxidizing Low-alloy stels for toughness, short circuiting mode, Copia by the Ameian Nelng Society Satu 05 135401 1997AUS C5-b 89 O78426S5 OOO2SbO 8 mm 2 Ties Aetecton of Gases ta wth ay Mane enero Lamsternet aol ceca fs {0 prevent air contamination on back of weld area, circuit transfer mode rather than either the spray o globular transfer mode with theie inherently higher energy input. Joint tolerances (gap) and weld size and length may also be a major influence in selet tion of the process mode to be used. ‘The desired weld bead cross section (including re- inforcement, fusion pattern, and penetration) can be controlled by the shielding gas selection. Proper shielding gas selection can bean important factor to assure, for instance, good fusion characteristics when welders may be extended to maintain their gun in an optimum position, 4.3.2.3 Appearance, The appearance of the weldment is not of technical concern, but may be important. Smooth and spatter free weld beads on a product in an area highlighted in the purchaser's view are cited as a sales factor in many instances, ‘The spray arc and the short circuiting modes of ‘metal transfer will produce the smoothest and neat- est-appearing welds. Smooth and spatter-Iree areas adjacent to GMAW welds may also be required to assure proper fits in subsequent final assembly operations. 4.3.3 Electrode Selection. The selection of the Welding clectrode should be based principally upon ‘matching the mechanical properties and the physi cal characteristics of the base metal (see 4.2 and Ta ble 5), Secondary consideration should be given to items such as the equipment to be used, the weld size (deposition rates to be utilized), existing clec- trode inventory, and materials handling systems. 4.3.3.1 Equipment. The electrode package size should be compatible with the available handling ‘equipment. The package size should be determined by acost evaluation that considers product volume, change time versus the consideration of available space, inventory cost, and the materials handling system. 4.3.3.2 Weld Size. The electrode diameter should be chosen to best fit the requirements of the weld size and the deposition rate to be used, 4.3.3.3 Standardization and Inventory. Evelua- tion of each welding job on its own individual merit, would require an increasingly larger inventory with Cony by he Arcana Sac he So ico TSska" ar“aus C5-b 89 mm O7S42bS OODZEEE T Mm Table 4 Selection of Gases for GMAW with Short Circuiting Transfer ‘Shielding Gas ‘Advantages "75% argon ¥25% COs 75% argon 425% CO ‘Less than 1/8 jn, (3.2 mim) thick; high welding speeds without burn-thru; ‘minimum distortion and spatter. More than 1/8 in, (3.2 mm) thick; minimum spatter; clean weld ‘appearance; good puddle control in vertical and overhead positions. CO; Deeper penetration; faster welding speeds. Stainless steel 90% helium +7.5% argon+2.5% CO> 60-70% helium = Mini +25.35% argon ¥4-5% COs 75% argon +25% Low-alloy steel [No effect on corrosion cesistance; small heat affected zone; no undercutting; minimum distortion im reactivity, excellent toughness; excellent are stability; wetting characteristics, and bead contour; litle spatter, Fair toughness; excellent are stability, wetting characteristics, and bead Co; ‘contour little spatter. ‘Argon & argon. + helium, Aluminum, copper ‘magnesium, nickel and their alioys an increasing number of jobs. Minimizing inven- tory requires a review of overall welding require- ‘ments in the plant, with standardization ofthe basic electrode composition and sizes as well as the elec- trode packages as the objective. This ean be accom- plished readily with minimum compromise since ‘quite broad and overlapping choices are available. 4.3.3.4 Materials Handling Systems. ‘The elec- trode package size should also take into account the requirements for handling. Generally speaking, one individual can be expected to change an electrode package weighing up to 60 Ib (27 kg) without assist- ance, However, some systems are designed so that an individual can handle the larger spools up to 1000 Ib (454 kg) without additional assistance. The larger packages necessitate a handling system (lift truck or similar) capable of moving the electrode package from storage to the welding station when required for changing, or additional space is needed to accommodate at least two packages in order to avoid delays. 4A Welding Variables. Table 6 shows the relation ship between current and wire feed speed, travel speed, voltage and wire diameter. Some of the pro- cess variables to be considered are the following: (1) Deposition rate-travel speed (2) Wire feed speed (welding current) (3) Welding Voltage (4) Electrode extension (5) Travel Speed (6) Blectrode Diameter Copia by the Ameian Nelng Society Satu 05 135401 1997 ‘Argon satisfactory on sheet metal; agon-helium preferred on thicker sheet material (over 1/8 in. [3.2 mm). (7) Shielding gas (8) Gun angle 4.1 Deposition Rate. The deposition rate is de- fined as the actual amount of usable metal depos- ited per unit of time [generally in terms of pounds (kilograms) per hour]. Deposition rate is propor- tional to wire feed speed. See Figures 20, 22, 25, 27, 29, and 32. It is necessary to balance the deposition. ‘ale against the travel speed, since proper balance achieves an optimum rate of metal deposition for the weld joint design. This is particularly important in semiautomatic welding where weld quality de pends upon the physical movement capability of the welder to retain control of the weld puddle as travel speed is increased. The maximum travel speed limitation is about 25 ipm maximum (L1mm/s), although in some reported instances, the travel speed may reach as high as 150 ipm (64 mm/ In general, these higher rates of travel speed are attainable when the weld size is very small, the weld length is very short, the weld is along a straight line, or when optimum weld quality is not a factor. 44.2 Welding Current-Wire Feed Speed. After determining the optimum deposition rate for the application, the next step is to determine the weld- ing current and the related wire feed speed to achieve that deposition rate. In a practical applica- tion, the deposition rate is more accurately set, maintained, and reproduced by measurement of the wire feed speed rather than the welding current value.a AUS C5.b 85 Ml 0784265 O002L2 1 mm 2 lated to the proper arc length) is established to maintain are stability atthe chosen electrode feed speed or welding current level and to minimize spatter, ron 4.44 Electrode Extension. The basic control set- a tings for low conductivity electrode metals are very CONMATT TUBE much dependent upon the electrode extension. Variation in electrode extension results in a change TO fxcrRoDE quer in the electrical characteristics of the balanced 5% at 9 EXTENSION fo. WORK tem, as determined by the resistivity of the elec. NOZLE-TO. Jt orstance trode length between the contact tube and the are feX anc enc (Gee Figure 19) In essence, asthe contact tube-to-work distance is increased, the PR heating effect is increased, thus deoreasing the welding current (1) required to melt the electrode. Conversely, as the contact : tube-to-work distance is decreased, the PR effect Figure 19 - Electrode Extension Table 5 Recommended Filer Metals for GMAW AWS, Filler Metal Current Range Base Recommended Electrode Specification —Elestrode Metal ‘Electrode (Use Latest _Diameter Boe Tee Classification Edition) i mm =—_Amperes ‘Aluminum 1100 TERIT00 oF BRA0SS 003008 S075, and 3003,3004 ERI 100 or ERS356 1.2 90.280 aluminum 5052/5454 ERSSS4ERS356 AS.10 15 160-350 alloys or ERS183 24 225-400 5083,5086,5456 _-ERSSS6 or ERS356 32 350-475 €061,6063 'ER4O43 or ERS356 Mageesium —AZIOA ERAZSIAERAZI2A alloys AZ3IB,AZ61A 0.040 0150-300 ‘AZBOA ERAZ61AERAZ92A 3164 1.2 160.320" E108 ERAZ6LAERAZ92A, 116 156 —210-400¢ ZKQIA FRAZ6IAERAZ92A, AS94322 320-810 AZSBA,AZBIA V8 32 400.600" AzoIC ERAZ92A ‘AZ92A,AMIOOA —— BRAZ92A HKHAHM21A, HMBIA EREZ334 LALAIA EREZI3A Copper Deowidized and copper Bu 0035 09 150.300 copper CoN alloys EQN 004s 1.2 200-400 alloys Manganese ASG W616 230-450 bronze ECUAL-A? 3822.4 350-550 Aluminum bronze EcuALD oe TW bronze EQuSn-A “Spray Transfer Mode (continued) Copia by the Ameian Nelng Society Satu 05 135401 1997AUS CS5.6 89 MM O784265 0002463 3 mm cy Table & (Continued) Recommended Filler Metals for GMAW ‘AWS Filler Metal Current Range Base __._ Recommended Electrode Specification Hieatrode Metal Material Bleotrode (Use Latest amet ‘Toe ‘ype Classification in mii_—_Amperes Nickel 0000 OS = and nickel Monel**Alloy 400. ERNiCu-7 0.030 08 ~ alloys Inconel**Alloy 600 ERNiCrFe- Asta 0,035 09 100-160 0.04512 150-260 W616 100-400 Titanium Commercially Use a filer 0.03008 = and pure etal one oF #0 0.035 09) = titanium grades lower AS.16 004s 12 = alloys THOS Pa ERT/-0.2Pd THSAL-2.580 ERT/-5A1-2.580 ‘or coinm, pure ‘Austenitic Type 201 R308 002005 = stainless "Types 301,302, 0.02506 S steels 304 & 308 R308 0.03008 = 75-150 “Type 3041, ER3OSL. 00035 «09 100-160 ‘Type 310 R310 00s 12 140-310 ‘Type 316 ER3I6 Aso W166 280-450 ‘Type 321 ER321 56420. Ss ‘Type 347 R347 3322 = 16428 = Wwe 32 = Carbon Hot rolled or 'ER70S-3,0r ERTOS-1 002005 S steels cold-drawn ER708-2,ER 7054 0023 06 S plain carbon ER708-5,ER 708-6 0.030 «08 = 40-220 steels 0.035 09 60-280 ASSIS 0008S 1,.2 125-380 0.052 113 160-450 W616 295-475 56420 = 3022 = ifoeereer 3.2 = *Trademarkelnternational Nickel Co, is decreased, thus increasing the welding current requirements fora given wire feed speed. Long ex- tension may result in lack of fusion when welding thick material, This is why itis important to main= tain proper contact tube-to-work distance, Some typical values are % in, to te in, for short cire transfer and V2 in. to 1 in. (13 to 25 mm) for other types of metal transfer associated with GMAW Globular and axial spray), Table 6 illustrates the relationship between welding variables and the weld, 445 Travel Speed, Travel speed is a very ime Copia by the Ameian Nelng Society Satu 05 135401 1997 portant variable in gas metal arc welding. If a welder lets the welding are play on the weld pool instead of on the base metal, incomplete fusion or cold lap defect will result. A'liquid weld pool acts as an insulator between the high temperature welding arc and the base material, Therefore, to consistently obtain fused metal, the welding arc ‘must be continually positioned at the leading edge of the weld pool, 4.46 Guidelines for Operating Conditions. Figures 20 through 33 illustrate the basic concept of and provide basic information for establishing de-$e AUS C5-b 89 MM 0784265 COOZLL4 S mm position-rate to wire-feed-speed relationships. The distinction should be made between the melting rate (rate of melting of the electrode) and the depo ion rate (rate of actual metal deposited), The two are not the same, duc to arc and spatter loss, but arc related by the arc transfer efficiency. Also note that, the relationship between eleétrode feed speed and welding current can be altered by the electrode ex- tension (not shown in these figures), 5. General Joint Design ‘Typical weld joint designs and dimensions for the GMAW process, as used in the welding of steel, are shown in Figure 34(A) through (D). The dimensions indicated are those that have generally been found necessary to obtain complete joint penetration and acceptable reinforcement and weld bead cross see- tions with suitable welding procedures, ‘The deep penetration characteristics of the high energy modes of GMAW (i.c., not including short circuit or pulsed current transfer) present a poten- tial reduction in the quantity of required weld metal and, consequently, welding costs. However, care must be exercised in the reduction of groove weld. angles and depths, since penetration characteristics will tend to diminish due to greater absorption of are energy by the side walls as the groove narrows. This is in comparison to a square-groove weld joint for which most of the arc eneray is transmitted di- rectly into the interfuce. ‘The penetration can be readily predicted in fillet welding (sce Figure 35), where the side walls are generally at a 90° angle, Table 7 shows fillet size ro- duction possible with greater throat depth. Since the heat input is quite low with a short circuiting welding arc, the possibility of incomplete fusion de- fects is increased on heavier weldments, 6. Arc Spot Welding Are spot welding with GMAW requires the same equipment as previously described plus a special are timer fo control the are on time, and a special gun nozzle, The gun nozzle provides containment with vents, for shielding gas, maintains a constant contact tube height when placed on top of the joint to be welded, and helps shield the welder’s eyes from the are. Table 6 How Changes in Welding Variables Affect Wold OE ootoe ERE eI EE O° O° ee |>/ 0/0) < O}O}e|e 0/0] > 2 OlO|> |) O;O| ofolo|>l€jo| > ololole|>lol « Bl<)olslole Dro treet Qurme ester Copia by the Ameian Nelng Society Satu 05 135401 1997 A rence W cxousse * ie oumenr Leva anc MAMIANED By AD.USTAENT OFAWS CS-b 69 MM 0784265 OOOZGLS 7 mm : ‘nr @ sven Eun Ect Tee py Pose or Flt Wl ae 1. Fillet welds made with low energy GMAW modes (ie. sh “effective” throat depth a fillets made with the SMAW process. 2. In multiplespass welding, efletive penetration isa function of the first pass only. Applicable to both Nat ané horizon- tal singel pass welds. ‘J Inspection of fillet weld cross section should be made to assure adequate welding procedure for minimum effective a e WIRE FEED SPEED, IVCHES PER MINUTE circuit and pulsed current transfer) exhibit the same oes atta ea aso eco amo sn 7 ; “ J : 2 Py, ‘ § 10: é w 42 ge 2 AG ee j a a Fl : : | i ° ; : tt + on FE SCE, METERS PER MATE Figure 20 - Typical Melting Rates for Plain Carbon Steel e Copia by the Ameian Nelng Society Satu 05 135401 1997AUS C5-b 59 M@ O7842b5 OOOZbEb 7 ml 2 WIRE FEED SPEED, INCHES PER MINUTE oy 190. 290 _900_4g0 590690700 000 WELDING CURRENT, A(OCEP) Pose 460: 3 70 16 * WIRE FEED SPEED, METERS PER MINUTE Figure 21 - Typical Welding Currents Versus Wire Feed Speeds for Carbon Steel Electrodes WIRE FEED SPEED, INCHES PER MINUTE 0100 200 300 400500600700 800 a00 MELTING RATE, hg’ MELTING RATE, 7h WIRE FEED SPEED, METERS PER MINUTE Figure 22 - Typical Melting Rates for Aluminum Electrodes Copia by the Ameian Nelng Society Satu 05 135401 19970784265 OOOZEL7 O mm #8388 8 3 8 pee ee a WELDING CURRENT A(DCEP) om coe ogee ‘WIRE FEED SPEED, METERS PEA MINUTE Figure 23 Welding Currents Versus Wire Feed Speed for ER4043 Aluminum Electrodes e _ We KD SPEED, CHES Pag ERATE 08 § 8 & 8 & BB ep 2 iELDING CURRENT, A (OCEF) ° 3 Sl 8 Wine FED SPEED, METERS PER MINUTE Figure 24 — Welding Currents Versus Wire Feed Speed for ERS5356 Aluminum Electrodes: Sat ul 05 15:50AWS C5.b 89 MM 0784265 O002KL6 2 mm “ MELTING RATE, by » ‘Wine FEED SPEED, INCHES PER MINUTE 1g 20 moan 50 oo 790 ow. MELTING RATE, be 5 70 © * WE FEED SPEED, METERS PER MUTE Figure 25 - Typical Melting Rates for 300 Series Stainless Steel lectrodes. We FEED SAEED, NCHES PER ANTE 8 3 8 8 3 WELDING CURRENT, A (ocEP) oot ome ou 052 coe ont WARE FEEO SPEED, METERS PE MINUTE Figure 26 ~ Typical Welding Currents Versus Wire Feed Speeds for 300 Series Stainless Steel Electrodes Sat ul 05 15:5030 Sat ul 05 15:50 AUS C5-b 89 mM O7A4265 OOD2bbS ‘wine FEED SPEED, INCHES PER MINUTE gma am tG0 06% 700 ato oo : j ' fg 6 ete yg a e a ie g 2 ' é 5 0 % & Wine SEED SPEED, METERS PER MINUTE Figure 27 - Typical Melting Rates for ECu Copper Electrodes WWE FEED SPEED, NCHES PER NANUTE o € 888 8 8 8 8 {ine FEED SecED, NETERS PER MINUTE Figure 28 - Welding Currents Versus Wire Feed Speed for ECu Copper Electrodesoreuess 3 We FEED SPEED, NeHES Pen MINUTE 2190 ago 500 QO” S00 GON TOO 80000, MELTING RATE, vy MELTING RATE. Kom 3 . 7 % Ey WIRE FEED SPEED, METERS PER MINUTE Figure 29 - Typical Melting Rates for ECuSi-A Copper Electrodes e serena ot WELORG CURRENT, ADCER oor ° ° 3 = 8 \WRe F220 SPEED, MHETERS FER MINUTE Figure 30 - Welding Currents Versus Wire Feed Speed for ECuSi-A Copper Electrodes an Welg Society he oprah by thea Satu 05 135401 19972 Sat ul 05 15:50 AUS C5-6 84 O7a42b5 OOO2b7L 2 mM \WiRE FEED SPEED, RICHES PER MAINUTE. 9x0 490 600 990 1020 r290 1400 Y6C0 1000 2000, ‘ARGON SiHELONG GAS weLoiic CURRENT, A ]OCER & Df ® hm we mo mo WE FEED SPEED, METERS PER MINUTE Figure 31 - Typical Currents Versus Wire Feed Speed for Magnesium Electrodes Wane FEED SPEED, CHES PER MAUTE oe ee ae om oa - 3 : g & a 2 i, ofp ° pot A a at WIRE FEED SPEED, ETERS PER MINUTE Figure 32 - Optimum Short Circuit Transfer for Plain ‘Carbon Steel ElectrodesAUS CS+b 89 M@ O7842b5 OOO2G72 4 mm WIRE FEED SPEED, INCHES PER MINUTE a 8 #8 8 8 3 oon 002. \WELDING CURRENT, A (OCEP) ot oz. \WIRE FEED SPEED, METERS PER MINUTE Figure 33 - Optimum Short Circuit ‘Transfer for Carbon Steel Electrodes 6.1 Equipment Operation. ‘The welding gun is piaced in position against the workpiece and the sun's triggee is depressed to start the functions of thearc timer and the initiation ofthe are, The arcis maintained by the continuously-fed consumable electrode and melts through the top shect and fuses into the bottom sheet without relative travel, The time eyele is set to maintain the are until the melt through and fusing sequence is complet: i the spot weld has been completed, The electrode will continue to feed during the arc cycle and will pro- duce a slight convex reinforcement on the upper surface of the top sheet The controls on the are timer and their functions are as follows (1) Arc time potentiometer ~ regulates time that welding arc is sustained (2) Preflow time potentimeter ~ sets time at which gas valve opens prior to welding are initia tion (adjustable from 0 to 2 seconds) (3) Burnback time potentiometer ~ controls the delay of the welding contactor drop-out after the electrode feed motor stops and the distance that the electrode melts back from the weld surface (adjusta- ble form 0 to 0.5 seconds) 33 (4) Postflow time potentiometer ~ adjusts the time duration that shielding gas will low after weld- ing are stops (adjustable from 0 to 2 seconds). 6.2 Effect of Process Variables on Weld Characteris- tics. Weld diameter at the interface and reinforce- ‘ment are two characteristics of GMAW spot weld which determine whether the weld will satisfy the intended service. Each of the three major process variables of weld current, voltage, and weld time af- fect one of both of these factors. Arc voltage and. welding current are relatively high for spot welding in comparison to typical GMAW values, but the time cycle for making spot welds ranges from only 0.3 seconds to 5 seconds. Guidelines for these vari- ables are presented in Tables 8 through 12, 6.2.1 Current. Current has the greatest effect on penetration. Penetration is increased by using higher currents with corresponding increase in the wire feed speed. Increased penetration will gencr- ally result in a larger weld diameter at the inter- face. 6.2.2 Arc Voltage. The arc voltage has the great- cst effect on the are spot weld shape, In general, with ‘current being held constant, an increase in the arc voltage will increase the diameter of the fusion zone and the diameter of the weld nugget. However, it also causes a slight decrease in the reinforcement. ‘Are voltages that are too high create heavy spatter conditions. 6.2.3 Weld Time. Welding conditions should be selected that produce a suitable weld within a time of 20 to 100 cycles of a 60 Hz. current (0.3 to 1.7 seconds) to join base metal up to 0.125 in, (3.2 mm) thick. Time up to 300 cycles (5 seconds) may be nec essary on thicker materials to achieve adequate strength. The penetration, weld diameter, and rei forcement height generally increase with increased weld time. 6.2.4 Polarity. Most applications of gas metal are spot welding employ direct current, electrode posi- tive, Electrode negative can be used under special conditions when low penetration is required. 6.3 Joint Design, Gas metal are spot welding may bbe used to weld lap joints in plain carbon steel, alu- ‘minum, magnesium, stainless stecl, and copper bearing alloys. Metals ofthe same or different thick- Copia by the Ameian Nelng Society Satu 05 135401 1997AWS C566 85 Mm O7842b5 OO02b73 b me M Eo oe ayy ao =] TS; yA fa = Sf von gee SS See ee = || ‘he si nance scomccnoe smmvnowrantomenes | 7 wane UD; ese Det TYE ro vs == Te[f=1716 Max 10° 1015" Theta U) , sit econo ron e@ ‘Sayan GROOVE JOWTS WELDED FROM (One ibe wi axcxNG SAG ad rie pad, Se i ed DOVRE v GROOVE JOWNTS WELDED FROM BOTH SES ht CxS Cet 70 16° ST eon pecan ron |® = VOMAK C= 110 mA ves a= 6a ionzowra nos SINGLE v.cROOVE JOMTS WELDED FON ate neve anoove owe WeADED “ALL BRVENSIONG Wi NGHES EXCEPT ANGLES pe staan ine “ ane Figure 34 - Typical Weld Joint Design for GMAW (Steel) an Welg Society he oprah by thea Satu 05 135401 199789 _M™ 0784265 0002674 8 mm * sam 7 osinons N snaute vvovmelle ohn SNGLE BevEL GROOVE JOINTS WELDED FROM Fr ic mE Peet. vievoavie JontREcoUNENOED FOR SSNGLE U-aRoOvE JNTS WELDED FROM samc oe JOINT RECOMMENDED FOR ae JONTS WELDED FROM 0 59 20s mm 54 WELD IN FLAT Position Wei HORIZONTAL, Posmmion MATERIAL 080 062 in. THK, ASTM A26Q/A285 SLEQUVALENTS. (A) 80in x80in, i mm (@) 25in x80in. (6) 25in x 80M, o28 34 (0) 80im ¥ 80in 038 85 ee on a (6) 35im x 062 050 tea + 45° BEVEL ON ONE SIDE 062 6 626 6 28 84 a8 50 50 2 80. 200. igure 51 - Example of Workmanship Sample Copia by the Ameian Nelng Society Satu 05 135401 1997AWS C5-b 64 MM O784265 OOD2b44 3 mu @@@ ere ~ seavence oF assematy MATERIALS @® 20 sTANOARD BLACK PPE 40 LONG © 20 stanoaRo BLACK PIPE 60 LONG © 15 staNDARO BLACK FFE 4.0 LONG © 038 x60%60 LONG AAI A285 © 038%50x60LONG — (45° BEVEL) A2H2 © 075%60%60L0NG A816 © 028 x 10x60 LONG A36 NOTE: ALL DIMENSIONS ARE IN INCHES Figure 52 - Workmanship Specimens Copia by the Ameian Nelng Society Satu 05 135401 1997 05 15 012 22 O18 4 025 6a 038 95 80 127 076 9 10 2% 15 28 20 a 40 a2 50 127 60. 183 35AUS CS-b 67 M™ O7S42E5 OOOZE4S 5 mm siento e@ FRACTURING FRACTURING 56 TMaxiMuM DEPTH OF NOTCH = 1/2 ACTUAL THROAT (A) REIVFORCING WELDS (8) NOTCHING Figure 54 —~ Methods for Facilitating Fillet Weld Fracture 344 19 FLANGE TO BE STRAGHT AND BU INTMNATE CONTACT ‘With SQUARE MACHINE Coc Or WEB MEMBCR [ALONG ENTIRE LENGTH TO INSURE MANDALA Restnant Figure 53 ~ Preparation of Filler Weld Break Test Specimen si EaUVALeNTS 1 —| ia t a8 W va i a8 Fi Bin-—+| ¢ STaNDARO a5¢ nee 2 ban o 5 % Sue 2 an 14 a 2 EOFWELDF Ve aft cH | Twceesst | 38 1 | twemesstT 3nd haa wom Pa oe ie NOTE: ALL OMIENSIONG ARE WERE Figure 55 — Longitudinal Fillet Weld e Shearing Specimen After Welding Sat ul 05 15:50AUS C5-b 84 MM O764265 OO02L96 7 mw 37 1 BERETS es reser Tin] ‘SI EQUIVALENTS 1 tf T = alate i i = t i | a i 25 Ret i [em a 14 = sPeomreo sie T= sre a OF FILLET WELD PLUS AT LEAST pvan 4 STANDARD 45° Fucet WeLbs, NOTE: ALL DIMENSIONS ARE IN INCHES DIMENSIONS SHOULD BE ALTERED TO ALLOW FOR +e PENETRATION CAPABILITIES OF THE PROCESS FOR Th 5 [BOTH THE LONGITUDINAL AND THE TRANSVERSE 1 5 setorien FILLET WELD SHEAR SPECIMEN (SEE SECTION 5} We OF WELD PLUS AT LEAST 1/8 in. Figure 56 - ‘Transverse Fillet Weld Shearing Specimen ‘THESE EDGES MAY BE. FLAME CUT AND MAY OR MAY NOT BE MACHINED. t saa 4 | 11 APPROX. | ——S—a— RADIUS 1/16 MAX P “a 4 ‘THE WELD REINFORCEMENT AND MAXIMUM SZE THE BACKING SHALL BE REMOVED FLUSH WITH THE BASE METAL, FLAME CUTTING MAY 8 USED FOR THE REMOVAL OF THE MAJOR. PART OF THE BACKING STRIP, PROVIDED AT LEAST 1/8 in. OF ITS THICKNESS '$ LEFT TO BE REMOVED BY MACHINING OR GRINDING, SINGLE PASS FLLET WELD 2/8 in, Figure 57 - Longitudinal Fillet Weld Specimen After Machining Figure 58 - Fillet Weld-Soundness Test Copia by the Sat dul 05 135401 ‘SpecimensCopvinh by the “RUS CS-6 49 MB O7842b5 OOO2LS7 5 mm ss THESE EoGes MAYBE YACINED eH Wt BASE METAL sv couvaenrs pe ee | a a ve te — woe 1 oT “og Al we Ss i {ll a4 8 Ye Law ence of ye 8 noes race 2 f oes wor ex tn, NOTE: ALL DIMENSIONS ARE IN INCHES. Figure 59 — Reduced-Section Tension Specimen (Plate) MACHINE THE MINIAUM AMOUNT NEEDED TO OBTAIN PLANE PARALLEL, FAGES OVER THE 2/4 in. WIDE REDUCED SECTION THESE EDGES MAY BE we Par uy vs EDGE OF WIDEST THIS SECTION MACHINED, FACE OF WELD PREFERABLY BY MILLING NOTE; ALL DIMENSIONS ARE IN INCHES. Figure 60 - Reduced-Section Tension Specimen (Pipe) Satu 05 135401 1997AUS C5-b 89 M™ O784265 000298 0 mm 9 THESE EDGES MAY BE FLAME CUT AND MAY OR MAY NOT BE MACHINED Ae Max, T ue i a rs NOTE: WELD REINFORCEMENT AND BACKING STRIP, IF ANY SHALL BE REMOVED FLUSH WITH THE SURFACE OF THE SPECIMEN. IF A RECESSED STHP IS USED THIS SURFACE OF THE SPECIMEN MAY BE MACHINED TO ‘A DEPTH NOT EXCEEDING THE DEPTH OF THE RECESS TO REMOVE THE STRIP, EXCEPT THAT IN SUCH CASES THE THICKNESS OF THE FINISHED ‘SPECIMEN SHALL BE THAT SPECIFIED ABOVE. e NOTE: ALL DIMENSIONS ARE IN INCHES Figure 61 - Face- and Root-Bend Specimen (Plate) NOTE: WELD REINFORCEMENT AND BACKING STRIP, IF ANY SHALL BE REMMOVED FLUSH WITH THE SURFACE OF ‘THE SPECIMEN. IFA RECESSED RING IS USED, THIS SURFACE OF THE SPECIMEN MAY BE MACHINED TO ‘A DEPTH NOT EXCEEDING THE DEPTH OF THE RECESS TO REMOVE THE RING, EXCEPT THAT IN ‘SUCH CASES THE FINISHED SPECIMEN SHALL BE THAT SPECIFIED ABOVE. NOTE: ALL DIMENSIONS ARE IN INCHES. SL EQUIVALENTS THESE EDGES MAY BE FLAME CUT AND. ia, em MAYOR MAY NOT BE MACHINED [R= 1/16MAX wie 18 a=20/4 we 32 co aes au —=— os |-_—» n——— et Figure 62 ~ Face- and Root-Bend Specimen (Pipe) Copia by the Satu 05 135401 1997© If FLAME CUT, NOT LESS THAN {VB in, SHALL BE MACHINED FROM EDGES et CUT ALONG THIS LINE WHEN T EXCEEDS 1.1/2 in EDGE MAY BE FLAME CUT AND MAY OR MAY NOT 8E MACHINED, ae | a mei ee Dive 142 Et w NOTE: ALL DIMENSIONS ARE IN INCHES, Figure 63 - Side-Bend Specimen ner of work) designed to provide an example of the actual production application. (2) Reduced Section Tension Test (for tensi strength) (3) Free Bond Test (for ductility) (4) Root Bend Test (for soundness) (5) Face Bond Test (for soundness) (6) Side Bend ‘Test (for soundness) 95.3 Test for All Welds. Prototype structures built to welding procedures based upon previous produc- jon experience are advantageous in some applica- tions. These structures are then field tested under ‘actual service conditions or under accelerated labora tory testing to provide a correlation between the weld- ing procedure and the actual service requirements. 10. Recommended Safe Practices 10.1 Seope. ‘These recommended safe practices are for use with the gas metal arc welding processes only. They are designed to protect personnel from injury and illness and to guard against property damage. 10.1.1 For detailed safety information, refer to the manufacturer's instructions and the latest edi- tion of ANSI/ASC 249.1, Safety in Welding und Cutting (published by American Welding Society). For mandatory Federal safety regulations estab- lished by the U.S. Labor Department's Occupa- tional Safety and Health Administration (OSHA), refer to the latest edition of OSHA standards Code Copia by the Ameian Nelng Society Satu 05 135401 1997 of Federal Regulations, Title 29 CFR 1910 (General Industry) available from the Superintendent of Documents, U. S. Printing Office, Washington, D.C. 20402. Other standards may also apply such as 29 CFR 1915 for use in shipyard fabrication. 10.1.2 This document addresses potential hazards associated with the gas metal arc welding processes. No attempt has been made to include all hazards re- sulting from misapplication of the process. 10.1.3 The following potential hazards are con- sidered to be of sufficient magnitude to be included within the scope of this document, (1) Fumes and gases (2) Radiation (non-ionizing) (3) Blectrie shock (4) Noise (5) Other factors 10.2 Discussion of Potential Hazards 10.2.1 Metal Fumes are extremely small (sub-mi- ron) particles produced by the vaporization and subsequent recondensation of metals. Health hhazards associated with these depend on the toxic- ity ofthe specific meotal(s) and their concentration and form in the fume. 10.2.1.1 The composition of welding fumes is dependent on the clectrode being used, the alloy be ing welded, welding process utilized, and the coat- ings on the base metal. The relationship of the welder’s head with respect to the fume, and the ef- fectiveness of control measures, such as ventilation and personal protective equipment, are critical fac- {ors in influencing the welders exposure, 10,2.1.2. Gas metal are welding is used to weld all of the steels and many alloy metals with bases of chro- ‘mium, nickel, aluminum, and copper. The fumes as- sociated with the gas metal-are welding generally are much less dense than those produced by either shielded metal are welding or flux cored are welding because shielding does not depend on the decomposi- tion of a flux coating. Nonetheless, excessive flime concentration can be encountered ifadequate ventila- tion is not provided. The ventilation and protection requirements listed in ANS/ASCZ49.1 should be fol- lowed. These fumes will contain iron oxide when steel is being welded and significant levels of the other met- als when alloys are welded,AUS CS.b 89 MM O784265 0002700 5 mm 6 wo S w So as | } Fone i i axis units 6a ¢ I «| vernca. | mane ‘xis unas i foraee | TAGULATION OF POSITIONS OF FILLET WELDS DIAGRAM INCLINATION ROTATION POSITION REFERENCE OF AXIS OF FACE FATA Te we HORZONAL 2 wore? 2S WTS HORIZONTAL BO tote® 425, TSO, TOF to 126° OvERHEAD CO WA ak Cee WS to8" 125 wo 205° venrica, «2 JS t080 128" 10205 Notes: 1. THE HORIZONTAL REFERENCE PLANE IS ALWAYS TAKEN TO LIE BELOW THE WELD UNDER CONSIDERATION. 22. THE INCLINATION OF AXIS iS MEASURED FROM THE HORIZONTAL REFERENCE PLANE TOWARD THE VERTICAL. REFERENCE PLANE 3. THE ANGLE OF ROTATION OF THE FACE IS DETERMINED BY A LINE PERPENDICULAR TO THE THEORET: ICAL FACE OF THE WELD WHICH PASSES THROUGH THE AXIS OF THE WELD. THE REFERENCE POSt. TOW (0°) OF ROTATION OF THE FACE INVARIABLY POINTS IN THE DIRECTION OPPOSITE TO THAT IN \VIHICH THE AXIS ANGLE INCREASES. WHEN LOOKING AT POINT P, THE ANGLE OF ROTATION OF THE FACE OF THE WELD IS MEASURED IN A CLOCKWISE DIRECTION FROM THE REFERENCE POSITION (0") e Figure 64 - Position of Copy by the Satu 05 135401 1997a AUS C5. 64 Mm 0784265 0002701 7 mm Axis LIMITS FOR C, VERTICAL \ => FORABB OS SGpe— oe omzontas Pane Ps ~ ‘TABULATION OF POSITIONS OF GROOVE WELDS "oN DIAGRAM INCLINATION ROTATION, POSITION REFERENCE OF AXIS OF FA A Owe ar Te HonsonTaL «ows AD ovenvead © war ag 9 2 veRTICAL ar toao" “Owe? FOR GROOVE WELDS IN PIPE THE FOLLOWING DEFINITIONS SHALL APPLY: HORIZONTAL FIAED POSITION. WHEN THE AXIS OF THE PIPE DOES NOT DEVIATE BY MORE TAN 30° FROM THE HORIZONTAL PLANE AND THE PIPE (S NOT ROTATED DURING WELDING. HORIZONTAL ROLLED POSITION: WHEN THE AXIS OF THE PIPE DOES NOT DEVIATE BY MORE THAN 80° FROM THE HORIZONTAL PLANE, THE PIPE (8 ROTATED DURING WELDING, AND THE WELD METAL IS DEPOSITED WITHIN AN ARC NOT YO EXCEED 16° ON EITHER SIDE OF A VERTICAL PLANE PASSING THROUGH THE AXIS OF THE PIE. VERTICAL POSITION: WHEN THE AXIS OF THE PIPE DOES NOT DEVIATE BY MORE THAN 10° FROM THE VERTICAL POSITION, (THE PIPE MAY OR MAY NOT BE ROTATED DURING WELDING )* “POSITIONS IN WHICH THE AXIS OF THE PIPE DEVIATES BY MORE THAN 10° AND LESS THAN 80° FROM THE VERTICAL SHALL [BE CONSIDERED INTERMEDIATE. e Figure 65 - Position of Groove Welds Copia by the Ameian Nelng Society Satu 05 135401 1997AUS C5-b 89 Mm O7842b5 0002702 9 mm Most low carbon electrodes are copper coated. ‘The amount of copper fume generated is directly proportional to the overall copper content of the electrode and base metal, 10.2.1.3 The physiological effects of the fumes produced will vary with the metal involved. Expo- sure must be evaluated on individual fume expo- sure basis. 10.3. Gases 10.3.1 Ozone 10.3.1.1 Ozone is a gas with a very pungent distinctive odor. It may be injurious to the lungs, upper respiratory system, and eyes. 10.3.1.2 The ultraviolet light emitted by the GMAW are acts on the oxygen in the surrounding, atmosphere to produce ozone, the amount of which will depend upon the intensity and the wave length of the ultraviolet energy, the humidity, the amount of screening afforded by any welding fumes, and ‘other factors. The ozone concentration will gener- ally be inereased with an increase in welding cu rent, with the use of argon as the shielding gas, and. when welding highly reflective metals, Ifthe ozone cannot be reduced to a safe level by ventilation or process variations, it will be necessary to supply fresh air to the welder either with an air supplied respirator or by other means, 10.3.1.3 Ozone exposures during typical weld- ing operations are generally below accepted guide- lines. Certain conditions, such as welding in confined spaces or on highly reflective surfaces us- ing argon-rich gases, may result in exposures ex- ceeding published limits. 103.14 The lack of a pilot source for ozone generation makes it important to measure expo- sures in both the welder’s and helper’s breathing zones. Exposure standards are presented as eight- hour averages, making it difficult to evaluate expo- sures using grab sample techniques. 10.3.1.5 Since ozone is produced by ultravio- let radiation, generation of ozone away from the arc is possible. This can be aggravated by surfaces reflective to ultraviolet radiation, For this reason, focal exhaust ventilation at the are may not suffi- ciently control exposures to ozone, use of dilution Copia by the Ameian Nelng Society Satu 05 135401 1997 6 ventilation may also be necessary. If welding is per- formed in confined spaces, the ventilation and per- sonal protection requirements set forth in the latest edition of ANSVASC 249.1 will provide adequate protection, if followed, 10.3.2 Oxides of Nitrogen 10,3.2.1 Oxides of nitrogen may be injurious to the lungs, upper respiratory system, and eyes. 10.3.2.2 Nitrogen dioxide is the end result of a reaction between atmospheric nitrogen and oxygen and the electric arc, The intermediate, nitric oxide converts to nitrogen dioxide at a rate slow enough for both substances to be present. While both sub- stances have similar modes of action, nitrogen diox- ide is the more toxic of the two and has a corre- spondingly lower exposure limit, 10.3.2.3 Certain welding operations may gen- erate significant amounts of oxides of nitrogen. These processes should be evaluated. If problems are detected, the provisions set forth in the latest edition of ANSI/ASC 249. for ventilation will pro- vide adequate protection, 10.3.3 Carbon Monoxide 10.3.3.1 Carbon monoxide (CO) is a colorless, tasteless, and odorless gas. It combines with hemo- Blobin in red blood cells to form carboxyhemo- globin which interferes with the oxygen carrying ‘capacity of the blood. Thus, chemical asphyxiation may result 10.3.3.2 Significant carbon monoxide concen- trations may be generated from CO; gas metal arc ‘welding. Concentrations of CO are higher in the ‘welding plume, Where concentrations are exces- sive, provide adequate ventilation in accordance with ANSVASC 249.1, 10.3.4 Chlorinated Hydrocarbon, 10.3.4.1 Decomposition products of chlori- nated hydrocarbon can include toxic gases such as phosgene, hydrogen chloride, and chlorine, These products may be injurious to the lungs, upper respi- ratory system, eyes, and skin, 10.3.4.2 Experimental evidence has shown that chlorinated hydrocarbon vapors in the visinity“AWS C5-b 69 mm 0784265 0002703 0 mm of an are (even though notin direct contact with the are) decompose rapidly. The decomposition is caused by ultraviolet radiation from the are rather than by the high temperature of the arc. Although the concentration of chlorinated hydrocarbon va- prs may be too low to be detectable by the sense of smell, welding in areas containing chlorinated hy-

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