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    Exp 7

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    utsho das

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    Exp 7

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    1711027 -exp 7

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    Exp 7

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    Department of Materials and Metallurgical Engineering

    Bangladesh University of Engineering and Technology

    Experiment Number : 07

    Experiment Name : Study of Gas Tungsten Arc Welding (GTAW) and Gas Metal Arc Welding (GMAW)

    Submitted By:

    Name : Utsha Das

    Student Number : 1711027


    Course Number : MME 348
    Name of the Course : Metal Joining Technology Sessional

    Date of Performance : 28-12-2021

    Date of Submission : 08-02-2022


    38
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    Abstract
    This experiment's primary objective is to familiarize oneself with the equipment and processes of GTAW and GMAW.
    Two stainless steel sheet plates were welded with linear polarity using TIG (GTAW). MIG (GMAW) was utilized to
    join two moderate sheet plates with reverse polarity.
    Introduction
    Gas-tungsten arc welding (GTAW) is a method of joining metals by applying heat and melting [1]. A torch is utilized
    to hold a non-consumable tungsten electrode during this procedure. The flame shielding gas is employed to
    safeguard the electrode, molten weld pool, and solidifying weld metal against environmental contamination. An
    electric arc is generated when an electrical current flows through an ionized and conductive shielding gas [2]. GTAW
    is restricted to full penetration in a single pass, with a maximum weld plate thickness of approximately 3 mm. The
    voltage begins at 1015V, and the arc current ranges from 30 to 150A.The typical weld pace during GTAW is 75-150
    mm/min. During this procedure, the flame containing the tungsten electrode is linked to a shielding gas cylinder
    and the power source via an opposite terminal. Additionally, the electrode is in contact with a copper conduit chilled
    with water. [1] Welds from GTAW are of exceptional quality, devoid of defects or spatters. In addition, it can be
    utilized with or without infill metal. Furthermore, this method permits precise regulation of root pass weld
    penetration. GTAW processes have the disadvantages of slower deposition rates and being less cost-effective than
    consumable electrode arc welding processes. GTAW is alternatively referred to as TIG (tungsten-inert gas) welding.
    [2] In contrast, gas metal arc welding (GMAW) is an arc welding technique wherein a weld pool is connected to a
    continuous filler metal electrode via an arc. Shielding is achieved in this procedure by utilizing an externally supplied
    gas without the need for pressure application. GMAW is a procedure of fusion welding. The electrode utilized in this
    procedure is edible. The shielding vapor is employed externally to safeguard the molten weld reservoir. In contrast
    to shielded metal arc welding, gas metal arc welding employs a continuously fed electrode. The electric arc induces
    melting in both the filament and the basal material. GMAW is an alternative term for metal inert gas (MIG) welding.
    Carbon steel is frequently welded using this technique. Gas metal arc welding has several significant advantages
    over other fusion welding processes, including the ability to achieve quicker travel velocities, a cleaner process, a
    reduced skill requirement for operators, and an automation-friendly workflow [3]. Complex and expensive welding
    apparatus, reduced portability, high levels of radiated heat, and arc intensity, among others, are some
    disadvantages of this method [2].

    Equipment and Accessories

    Gas Tungsten Arc Welding (GTAW):


    • Arc Welding Power Source
    • Shielding Gas Cylinder or Supply
    • Welding Torch
    • Welding Rod
    • Shielding Gas Hoses
    • Shielding Gas Fittings
    • Tungsten Electrodes
    • Stainless Steel Sheet
    • Welding Shield

    40
    Gas Metal Arc Welding (GMAW):
    • Arc Welding Power source
    • Shielding Gas Cylinder
    • Gas Regulator
    • Shielding Gas Flowmeter
    • GMAW Welding Gun
    • Mild Steel Electrode
    • Wire Feeder
    • Mild Steel Sheet (Workpiece)
    • Welding Shield

    Experimental Methodology
    Gas Tungsten Arc Welding (GTAW):

    • At first, two pieces of Stainless Sheet (SS) were taken and cleaned properly.
    • The sheets were placed properly, and dimensions were measured carefully.
    • The hose connected the welding torch with the power supply.
    • Straight polarity was used to complete the power supply connections.
    • Finally, arc was initiated.
    • Filler rod was used lastly to do the welding in a single pass.

    Gas Metal Arc Welding (GMAW):


    • At first, two pieces of Mild Steel plate were taken and cleaned properly.
    • The sheets were placed properly, and dimensions were measured carefully. The hose was
    used to connect the welding gun.
    • Reverse polarity was used to complete the connections with the power supply.
    • The electrode used here was continuously fed.
    • Finally, welding was completed in three multiple passes.

    Results and Discussion

    Figure 1: TIG Welded Specimen Figure 2: MIG Welded Specimen

    As we can see from Figure 1, the specimen welded with GTAW has a very clean and narrow welding pool.
    This type of characterization is due to non-spattering and single-pass welding [2]. The weld beads are
    41
    produced autogenously at very high speeds. Some defects might be present in this welding, like cracks,
    porosity, lack of fusion, undercut, whiskers, etc, which are not visible macroscopically. [4] The main
    reasons behind these defects are poor gas coverage, too much amperage, improper arc length, dirty filler
    metal, craters, etc. [5]. Figure 2 represents a specimen welded with MIG. Here, we can see the weld pool
    is wider and deeper, which means the deposition rate in this welding is higher than TIG. The welding is
    done in multiple passes. However, the weld beads are not as clean as TIG. There might also be some
    defects like burn-through, porosity, lack of fusion, craters, and cracks, etc. [6] These defects can be
    prevented by preparing the joints sufficiently wide, proper gun angle, clean joint faces, amperage control,
    increasing heat input, shorter arc, and less voltage. [7]

    Conclusion
    In this experiment, we studied the working principles of GTAW and GMAW. Two stainless steel plates
    were joined by TIG (GTAW) welding. On the other hand, two mild steel plates were joined by MIG (GMAW)
    welding. Both weldings used argon as shielding gas. Some defects were present in both welds, possibly
    due to improper amperage, arc length, human errors, etc.

    References

    [1] D. M. A. Rashed, METAL JOINING TECHNOLOGY.

    [2] AWS, WELDING HANDBOOK.

    [3] Corrosionpedia, "Gas Metal Arc Welding (GMAW)," [Online]. Available:


    https://www.corrosionpedia.com/definition/4389/gas-metal-arc-welding-gmaw.

    [4] J. Grill, "Welding Defects," [Online]. Available: https://weldguru.com/common-welding-defects/.

    [5] N. Peterson, "TIG Problems and Solutions," [Online]. Available:


    https://www.fabricatingandmetalworking.com/2011/09/10-common-tig-problems-and-solutions/.

    [6] Z. Guzman, "MIG WELDING DEFECTS," [Online]. Available:


    https://www.aedmotorsport.com/news/mig-welding-defects.

    [7] R. Verho, "MIG Welding Defects," [Online]. Available: https://weldingvalue.com/2021/02/howavoid-


    most-common-mig-mag-welding-defects/#1ed28ef4.

    42
    Answer to the Questions
    (a)

    The operating steps of GTAW are given below: [2]

    • A high-frequency generator is used to provide an electric spark.


    • Shielding gas allows the arc to be initiated. The spark here acts as a conductive path for the
    welding current through the shielding gas.
    • Torch is moved in a small circle to create the welding pool
    • A constant separation between the electrode and the workpiece is maintained.
    • Torch is moved slightly and tilted backward from the vertical direction.
    • Filler metal was added manually to the front end of the weld pool. Filler rod was used lastly
    to do the welding in a single pass.
    The operating steps of GMAW are given below: [2]

    • An arc is struck between the end of a wire electrode and the workpiece.
    • Both the electrode and workpiece melt and form a weld pool.
    • The wire is used for both heat source and filler metal for the joint.
    • Wire is fed through a copper contact tube which conducts welding current into the wire.
    • Electrode is fed continuously in this welding process.
    • Shielding gas is used to protect the weld pool from the surrounding atmosphere.
    • The process usually operates with the wire positively charged and connected to a power source
    delivering a constant voltage.
    • Welding was completed in three multiple passes.
    (b)

    The effects of polarity on GTAW and GMAW are given below: [1]

    DCEN Polarity: When the polarity is DCEN, the electrode polarity remains negative. As a result, electrons
    emit from the electrode and go to the workpiece. Oxide cleaning is impossible in this polarity.70% of the
    heat goes to the work piece and 30% to the electrode end. Penetration is deep and narrow. The
    electrode capacity is excellent for this type of polarity.

    43
    Figure 3: Effect of DCEN Polarity

    DCEP Polarity: For DCEP polarity, the electrode end is positive, and the workpiece is negative. As a result,
    electrons emit from the workpiece and go to the electrode end. Surface cleaning is possible here due to
    oxide cleaning action.30% of the heat goes to the work and other 70% goes to the electrode end.
    Penetration is shallow and wide. Electrode capacity is poor.

    Figure 4: Effect of DCEP Polarity

    AC Polarity: Polarity of the electrode and work piece alternates every half cycle.

    Figure 5: Effect of AC Polarity

    Oxide cleaning is possible in every half cycle when the electrode polarity is positive.50% heat goes to the
    work piece and other 50% goes to the electrode end. Penetration is medium and electrode capacity is
    good in this polarity.

    44

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