The Everyday Pocket Handbook for Gas Metal Arc Welding (GMAW) and Flux Cored Arc Welding (FCAW)
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1 The Everyday Pocket Handbook for Gas Metal Arc Welding (GMAW) and Flux Cored Arc Welding (FCAW) Number 4 in a series Compiled as a useful tool for on-the-job welding personnel by the AWS Product Development Committee 1
2 Edited by L. W. Myers Sr., Welding Engineer, Turbo Products Division, Dresser-Rand, Inc., Olean, NY 1997 by American Welding Society. All rights reserved Printed in the United States of America NOTE: Although care was taken in choosing and presenting the data in this guide, AWS cannot guarantee that it is error free. Further, this guide is not intended to be an exhaustive treatment of the topic and therefore may not include all available information, including with respect to safety and health issues. By publishing this guide, AWS does not insure anyone using the information it contains against any liability or injury to property or persons arising from that use. 2
3 Basic Safety Precautions... 4 Gas Metal Arc Welding... 6 Specifications and Classification System for Solid and Composite Filler Metals... 6 Shielding Gases Spray Transfer... 7 Shielding Gases Short Circuiting Transfer... 9 Globular-to-Spray Transition Currents Typical Arc Voltages Typical Currents vs. Wire Feed Speeds Carbon Steel.. 12 Typical Melting Rates Carbon Steel Typical Currents vs. Wire Feed Speeds Carbon Steel (Short Circuiting Arc) Typical Melting Rates Carbon Steel (Short Circuiting Arc) Typical Currents vs. Wire Feed Speeds Stainless Steel Typical Melting Rates Stainless Steel Typical Currents vs. Wire Feed Speeds Aluminum Typical Melting Rates Aluminum Typical Welding Conditions Carbon and Low Alloy Steels Typical Welding Conditions Stainless Steels Typical Welding Conditions Aluminum Wire Length per Pound of Wire Flux Cored Arc Welding Table of Contents 3 Specifications and Classification System Carbon Steel (CO 2 Shielding) (CO 2 Shielding) Carbon Steel (Self-Shielding) (Self-Shielding) Typical Deposition Rates Stainless Steel (Gas-Shielding) Stainless Steel (Gas-Shielding) Alloy Steels (Gas-Shielding) Alloy Steels (Self-Shielding) Typical Welding Procedures Stainless Steels (Gas-Shielding) Troubleshooting Mechanical Problems in GMAW and FCAW Troubleshooting Electrical Problems in GMAW and FCAW Welding Positions Basic Welding Symbols... 46
4 Material GMAW Filler Metal Specifications and Classification System AWS Spec. Filler Metal AWS Class.* Steel, carbon A5.18 ERXXS-Y Steel, low alloy A5.28 ERXXS-Y 6 X Designator Description Example ER70S-3 E70C-3 ER80S-B2 E80C-B2 Stainless steel A5.9 ERXXXY Stainless alloy (308, 410, etc.) ER308L EC308L Aluminum A5.10 ERXXXX-Y Aluminum alloy (4043, 5083, etc.) ER4043 Nickel A5.14 ERNiXX-Y Major alloying elements (Cr, Fe, Mo, etc.) ERNiCr-3 Copper A5.7 ERCuXX-Y Major alloying elements (Al, Ni, Si, etc.) ERCuAl-A2 Magnesium A5.19 ERXXYYY Major alloying elements (Al, Zn, etc.) ERAZ92A Titanium A5.16 ERTi-Y ERTi-5 *Legend E Filler metal may be used as an electrode R Filler metal may be used as a rod S Solid filler metal C Composite or stranded filler metal Y Designator (or combination of designators) that describe specific alloy, shielding gas to be used, diffusible hydrogen limit, etc. Refer to the appropriate AWS Filler Metal Specification shown in table for explanation.
5 Edited by L. W. Myers Sr., Welding Engineer, Turbo Products Division, Dresser-Rand, Inc., Olean, NY 1997 by American Welding Society. All rights reserved Printed in the United States of America NOTE: Although care was taken in choosing and presenting the data in this guide, AWS cannot guarantee that it is error free. Further, this guide is not intended to be an exhaustive treatment of the topic and therefore may not include all available information, including with respect to safety and health issues. By publishing this guide, AWS does not insure anyone using the information it contains against any liability or injury to property or persons arising from that use. 2
6 Basic Safety Precautions... 4 Gas Metal Arc Welding... 6 Specifications and Classification System for Solid and Composite Filler Metals... 6 Shielding Gases Spray Transfer... 7 Shielding Gases Short Circuiting Transfer... 9 Globular-to-Spray Transition Currents Typical Arc Voltages Typical Currents vs. Wire Feed Speeds Carbon Steel.. 12 Typical Melting Rates Carbon Steel Typical Currents vs. Wire Feed Speeds Carbon Steel (Short Circuiting Arc) Typical Melting Rates Carbon Steel (Short Circuiting Arc) Typical Currents vs. Wire Feed Speeds Stainless Steel Typical Melting Rates Stainless Steel Typical Currents vs. Wire Feed Speeds Aluminum Typical Melting Rates Aluminum Typical Welding Conditions Carbon and Low Alloy Steels Typical Welding Conditions Stainless Steels Typical Welding Conditions Aluminum Wire Length per Pound of Wire Flux Cored Arc Welding Table of Contents 3 Specifications and Classification System Carbon Steel (CO 2 Shielding) (CO 2 Shielding) Carbon Steel (Self-Shielding) (Self-Shielding) Typical Deposition Rates Stainless Steel (Gas-Shielding) Stainless Steel (Gas-Shielding) Alloy Steels (Gas-Shielding) Alloy Steels (Self-Shielding) Typical Welding Procedures Stainless Steels (Gas-Shielding) Troubleshooting Mechanical Problems in GMAW and FCAW Troubleshooting Electrical Problems in GMAW and FCAW Welding Positions Basic Welding Symbols... 46
7 Material GMAW Filler Metal Specifications and Classification System AWS Spec. Filler Metal AWS Class.* Steel, carbon A5.18 ERXXS-Y Steel, low alloy A5.28 ERXXS-Y 6 X Designator Description Example ER70S-3 E70C-3 ER80S-B2 E80C-B2 Stainless steel A5.9 ERXXXY Stainless alloy (308, 410, etc.) ER308L EC308L Aluminum A5.10 ERXXXX-Y Aluminum alloy (4043, 5083, etc.) ER4043 Nickel A5.14 ERNiXX-Y Major alloying elements (Cr, Fe, Mo, etc.) ERNiCr-3 Copper A5.7 ERCuXX-Y Major alloying elements (Al, Ni, Si, etc.) ERCuAl-A2 Magnesium A5.19 ERXXYYY Major alloying elements (Al, Zn, etc.) ERAZ92A Titanium A5.16 ERTi-Y ERTi-5 *Legend E Filler metal may be used as an electrode R Filler metal may be used as a rod S Solid filler metal C Composite or stranded filler metal Y Designator (or combination of designators) that describe specific alloy, shielding gas to be used, diffusible hydrogen limit, etc. Refer to the appropriate AWS Filler Metal Specification shown in table for explanation.
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