2-9.

Common GMAW Shielding Gases

This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shield-
ing gases have been developed over the years.

Gas Spray Arc Short Spray Arc Short Spray Arc Short
Steel Circuiting Stainless Steel Circuiting Aluminum Circuiting
Steel Stainless Aluminum
Steel
Argon All Positions5 All Positions

Argon + 1% O2 Flat & Horizontal5 Flat & Horizontal5

Fillet Fillet

Argon + 2% O2 Flat & Horizontal5 Flat & Horizontal5

Fillet Fillet

Argon + 5% O2 Flat & Horizontal5

Fillet

Argon + 8% Flat & Horizontal5 All Positions

CO2 Fillet

Argon + 25% Flat & Horizontal1 All Positions

CO2 Fillet

Argon + 50% All Positions

CO2
CO2 Flat & Horizontal1 All Positions
Fillet

Helium All Positions2

Argon + All Positions2

Helium
Tri-Mix4 All Positions

1 Globular Transfer 4 90% HE + 7-1/2% AR + 2-1/2% CO2

2 Heavy Thicknesses 5 Also for GMAW-P, All Positions
3 Single Pass Welding Only
 SECTION 3 − MODES OF GMAW TRANSFER

. GMAW transfer mode is determined by variables such as shielding gas type, arc voltage, arc current, diameter of electrode and wire feed speed.

3-1. Short Circuit Transfer

1 Short Circuit Transfer

Short circuit transfer refers to the
welding wire actually “short circuit-
ing” (touching) the base metal be-
tween 90 - 200 times per second.
With short circuit transfer, wire feed
speeds, voltages, and deposition
rates are usually lower than with oth-
er types of metal transfer such as
spray transfer. This makes short cir-
cuit transfer very versatile allowing
the welder to weld on thin or thick
1 metals in any position.
Limitations of short circuit transfer:
S A relatively low deposition rate
S Lack of fusion on thicker metals
S More spatter

. Short circuit transfer usually has

a crackling (bacon frying) sound
when a good condition exists.
2 Short Circuit Cycle
A - Electrode is short circuited to
base metal. No arc, and current
is flowing through electrode
wire and base metal.
B - Resistance increases in elec-
trode wire causing it to heat,
melt and “neck down”.
C - Electrode wire separates from
weld puddle, creating an arc.
Small portion of electrode wire
is deposited which forms a
2
weld puddle.
D - Arc length and load voltage are
at maximum. Heat of arc is flat-
tening the puddle and increas-
ing the diameter tip of elec-
trode.
E - Wire feed speed overcomes
heat of arc and wire
approaches base metal again.
F - Arc is off and the short circuit
cycle starts again.

Page 13
3-2. Globular Transfer

1 Globular Transfer
Globular transfer refers to the state of
transfer between short-circuiting and
spray arc transfer. Large globs of
wire are expelled off the end of the
electrode wire and enter the weld
puddle.
Globular transfer can result when
welding parameters such as voltage,
amperage and wire feed speed are
somewhat higher than the settings
for short circuit transfer.
Limitations of globular transfer:
S Presence of spatter
S Less desirable weld appearance
than spray arc transfer
S Welding is limited to flat positions
and horizontally fillet welds
S Welding is limited to metal 1/8 inch
(3 mm)or thicker

3-3. Spray Arc Transfer

1 Spray Arc Transfer

Spray arc transfer “sprays” a stream
of tiny molten droplets across the
arc, from the electrode wire to the
base metal.
Spray arc transfer uses relatively
high voltage, wire feed speed and
amperage values, compared to short
circuit transfer.

. To achieve a true spray transfer,

an argon-rich shielding gas must
be used.
When proper parameters are used,
the spray arc transfer produces a
characteristic humming or buzzing
sound.
Advantages of spray arc transfer:
S High deposition
S Good fusion and penetration
S Good bead appearance
S Capability of using larger diameter
wires
S Presence of very little spatter
Limitations of spray arc transfer:
S Used only on material 1/8 inch
(3 mm) and thicker (hand held)
S Limited to flat and horizontal fillet
weld position (except for some spray
transfer on aluminum)
S Good fit-up is always required as
there is no open root capability