1、1The EverydayPocket Handbook forGas Metal Arc Welding (GMAW) and Flux Cored Arc Welding (FCAW)Compiled as a useful tool foron-the-job welding personnel by theAWS Product Development CommitteeNumber 4 in a series2NOTE: Although care was taken in choosing and presenting the data in this guide, AWS can
2、not guarantee that it iserror free. Further, this guide is not intended to be an exhaustive treatment of the topic and therefore may not include allavailable information, including with respect to safety and health issues. By publishing this guide, AWS does not insureanyone using the information it
3、contains against any liability or injury to property or persons arising from that use.Edited byL. W. Myers Sr., Welding Engineer,Turbo Products Division,Dresser-Rand, Inc., Olean, NY 1997 by American Welding Society. All rights reservedPrinted in the United States of America3Basic Safety Precautions
4、 . 4Gas Metal Arc Welding . 6Specifications and Classification System forSolid and Composite Filler Metals. 6Shielding GasesSpray Transfer. 7Shielding GasesShort Circuiting Transfer 9Globular-to-Spray Transition Currents . 10Typical Arc Voltages. 11Typical Currents vs. Wire Feed SpeedsCarbon Steel 1
5、2Typical Melting RatesCarbon Steel 13Typical Currents vs. Wire Feed SpeedsCarbon Steel (Short Circuiting Arc) 14Typical Melting RatesCarbon Steel(Short Circuiting Arc) 15Typical Currents vs. Wire Feed SpeedsStainlessSteel 16Typical Melting RatesStainless Steel 17Typical Currents vs. Wire Feed Speeds
6、Aluminum. 18Typical Melting RatesAluminum 19Typical Welding ConditionsCarbon and LowAlloy Steels 20Typical Welding ConditionsStainless Steels. 21Typical Welding ConditionsAluminum 23Wire Length per Pound of Wire 24Flux Cored Arc Welding . 25Specifications and Classification System . 25Typical Curren
7、ts vs. Electrode Feed RatesCarbon Steel (CO2Shielding) 26Typical Deposition RatesCarbon Steel(CO2Shielding) 27Typical Currents vs. Electrode Feed RatesCarbon Steel (Self-Shielding) 28Typical Deposition RatesCarbon Steel(Self-Shielding) 29Typical Deposition RatesStainless Steel(Gas-Shielding) 30Typic
8、al Currents vs. Electrode Feed RatesStainless Steel (Gas-Shielding) . 31Typical Welding ProceduresCarbon and LowAlloy Steels (Gas-Shielding) 32Typical Welding ProceduresCarbon and LowAlloy Steels (Self-Shielding) 34Typical Welding ProceduresStainless Steels(Gas-Shielding) 36Troubleshooting Mechanica
9、l Problems in GMAWand FCAW 38Troubleshooting Electrical Problems in GMAWand FCAW 40Welding Positions 42Basic Welding Symbols. 46Table of Contents4Burn Protection. Molten metal, sparks, slag,and hot work surfaces are produced by welding,cutting, and allied processes. These can causeburns if precautio
10、nary measures are not used.Workers should wear protective clothing madeof fire-resistant material. Pant cuffs, open pock-ets, or other places on clothing that can catchand retain molten metal or sparks should not beworn. High-top shoes or leather leggings andfire-resistant gloves should be worn. Pan
11、t legsshould be worn over the outside of high-topshoes. Helmets or hand shields that provide pro-tection for the face, neck, and ears, and a headcovering to protect the head should be used. Inaddition, appropriate eye protection should beused.Electrical Hazards. Electric shock can kill.However, it c
12、an be avoided. Live electricalparts should not be touched. The manufacturersinstructions and recommended safe practicesshould be read and understood. Faulty installa-tion, improper grounding, and incorrect opera-tion and maintenance of electrical equipmentare all sources of danger.All electrical equ
13、ipment and the workpieceshould be grounded. The workpiece lead isnot a ground lead. It is used only to completethe welding circuit. A separate connection isrequired to ground the workpiece. The work-piece should not be mistaken for a groundconnection.Basic Safety Precautions5Fumes and Gases. Many we
14、lding, cutting,and allied processes produce fumes and gaseswhich may be harmful to health. Avoid breath-ing the air in the fume plume directly above thearc. Do not weld in a confined area without aventilation system. Use point-of-welding fumeremoval when welding galvanized steel, zinc,lead, cadmium,
15、 chromium, manganese, brass, orbronze. Do not weld on piping or containersthat have held hazardous materials unless thecontainers have been inerted properly.Compressed Gas Cylinders. Keep caps oncylinders when not in use. Make sure that gascylinders are chained to a wall or other struc-tural support
16、.Radiation. Arc welding may produce ultra-violet, infrared, or light radiation. Always wearprotective clothing and eye protection to pro-tect the skin and eyes from radiation. Shieldothers from light radiation from your weldingoperation.Refer to AWS/ANSI Z49.1, Safety in Weldingand Cutting, for addi
17、tional information.6GMAW Filler Metal Specifications and Classification SystemMaterialFiller MetalX Designator Description ExampleAWS Spec. AWS Class.*Steel, carbon A5.18 ERXXS-YEXXC-YTensile strength 1000 (psi) ER70S-3E70C-3Steel, low alloy A5.28 ERXXS-YEXXC-YTensile strength 1000 (psi) ER80S-B2E80
18、C-B2Stainless steel A5.9 ERXXXY Stainless alloy (308, 410, etc.) ER308LEC308LAluminum A5.10 ERXXXX-Y Aluminum alloy (4043, 5083, etc.) ER4043Nickel A5.14 ERNiXX-Y Major alloying elements (Cr, Fe, Mo, etc.) ERNiCr-3Copper A5.7 ERCuXX-Y Major alloying elements (Al, Ni, Si, etc.) ERCuAl-A2Magnesium A5.
19、19 ERXXYYY Major alloying elements (Al, Zn, etc.) ERAZ92ATitanium A5.16 ERTi-Y ERTi-5*LegendE Filler metal may be used as an electrodeR Filler metal may be used as a rodS Solid filler metalC Composite or stranded filler metalY Designator (or combination of designators) that describe specific alloy,
20、shielding gas to be used, diffusible hydrogen limit, etc. Refer tothe appropriate AWS Filler Metal Specification shown in table for explanation.7GMAW Shielding Gases for Spray TransferMetal Shielding Gas Thickness AdvantagesAluminum 100% Argon 0 to 1 in. (0 to 25 mm) Best metal transfer and arc stab
21、ility, least spatter65% Argon + 35% Helium 1 to 3 in. (27 to 76 mm) Higher heat input than straight argon; improved fusion characteristics with 5XXX series Al-Mg alloys75% Helium + 25% Argon Over 3 in. (76 mm) Highest heat input; minimizes porosityMagnesium 100% Argon Excellent cleaning actionSteel
22、carbon Argon + 3 to 5% Oxygen Improves arc stability; produces a more fluid and controllable weld puddle; good coalescence and bead contour; minimizes undercutting; permits higher speeds than pure argonArgon + 8 to 10% Carbon Dioxide High-speed mechanized welding; low-cost manual weldingSteel low-al
23、loy 98% Argon + 2% Oxygen Minimizes undercutting; provides good toughness8Steel stainless 99% Argon + 1% Oxygen Improves arc stability; produces a more fluid and controllable weld puddle; good coalescence and bead contour; minimizes undercutting on heavier stainless steels98% Argon + 2% Oxygen Provi
24、des better arc stability, coalescence, and welding speed than 1 percent oxygen mixture for thinner stainless steel materialsNickel, copper, and their alloys100% Argon Up to 1/8 in. (3.2 mm) Provides good wetting; decreases fluidity of weld materialArgon + Helium mixtures Higher heat inputs of 50 and
25、 75 percent helium mixtures offset high heat dissipation of heavier gagesTitanium 100% Argon Good arc stability; minimum weld contamination; inert gas backing is required to prevent air contamination on back of weld areaGMAW Shielding Gases for Spray Transfer (Continued)Metal Shielding Gas Thickness
26、 Advantages9GMAW Shielding Gases for Short Circuiting TransferMetal Shielding Gas Thickness AdvantagesCarbon steel 75% Argon+ 25% Carbon DioxideLess than 1/8 in. (3.2 mm)High welding speeds without burn-through; minimum distortion and spatter75% Argon+ 25% Carbon DioxideMore than 1/8 in. (3.2 mm)Min
27、imum spatter; clean weld appearance; good puddle control in vertical and overhead positions50% Argon+ 50% Carbon Dioxide Deeper penetration; faster welding speedsStainless steel 90% Helium+ 7.5% Argon+ 2.5% Carbon Dioxide No effect on corrosion resistance; small heat-affected zone; no undercutting;
28、minimum distortionLow alloy steel60 to 70% helium+ 25 to 35% Argon+ 4.5% Carbon Dioxide Minimum reactivity; excellent toughness; excellent arc stability, wetting characteristics, and bead contour; little spatter75% Argon+ 25% Carbon Dioxide Fair toughness; excellent arc stability, wetting characteri
29、stics, and bead contour; little spatterAluminum, copper, magnesium, nickel, and their alloysArgon andArgon + Helium mixturesOver 1/8 in. (3.2 mm) Argon satisfactory on sheet metal; argon-helium preferred base material10Globular-to-Spray Transition Currents for a Variety of ElectrodesWire Electrode T
30、ypeWire Electrode DiameterShielding GasMinimum Spray Arc Current, Ain. mmMild steel 0.030 0.8 98% Argon + 2% Oxygen 1500.035 0.9 98% Argon + 2% Oxygen 1650.045 1.1 98% Argon + 2% Oxygen 2200.062 1.6 98% Argon + 2% Oxygen 275Stainless steel 0.035 0.9 98% Argon + 2% Oxygen 1700.045 1.1 98% Argon + 2%
31、Oxygen 2250.062 1.6 98% Argon + 2% Oxygen 285Aluminum 0.030 0.8 Argon 950.045 1.1 Argon 1350.062 1.6 Argon 180Deoxidized copper 0.035 0.9 Argon 1800.045 1.1 Argon 2100.062 1.6 Argon 310Silicon bronze 0.035 0.9 Argon 1650.045 1.1 Argon 2050.062 1.6 Argon 270See page 11 for voltage settings.11Typical
32、Arc Voltages for GMAW of Various MetalsaMetalSpraybGlobular Transfer1/16 in. (1.6 mm) Diameter ElectrodeShort Circuiting Transfer.035 in (0.9 mm) Diameter ElectrodeArgon Helium25% Ar+ 75% HeAr + 1 to 5% O2CO2ArgonAr + 1 to 5% O275% Ar+ 25% CO2CO2AluminumMagnesium25263029281916Carbon steelLow alloy s
33、teelStainless steel2428282630301717181818191919212020NickelNickel-copper alloyNickel-chromium-iron alloy262626303030282828222222CopperCopper-nickel alloy302836323330242322Silicon bronzeAluminum bronzePhosphor bronze2828283232323030302823232323a. Plus or minus approximately ten percent. The lower vol
34、tages are normally used on light material and at low amperage; the higher voltagesare used on heavy material at high amperage.b. For the pulsed variation of spray transfer the arc voltage would be from 18 to 28 volts depending on the amperage range used.12Typical Welding Currents vs. Wire Feed Speed
35、s for Carbon Steel Electrodes13Typical Melting Rates for Carbon Steel ElectrodesExample:To find the melting rate for 0.045 in. carbon steel wire at a wire feed speed of 350 inches per minute, draw a line from 350 on the top scale down to the 0.045 in. curve (line); then draw a line from that interse
36、ction left to the Melting Rate scale and read 10.2 pounds per hour (lb/h).14Typical Currents vs. Wire Feed Speeds Carbon SteelShort Circuiting Arc15Typical Melting RatesCarbon SteelShort Circuiting Arc16Typical Welding Currents vs. Wire Feed Speeds for 300 Series Stainless Steel Electrodes17Typical
37、Melting Rates for 300 Series Stainless Steel Electrodes18Welding Currents vs. Wire Feed Speeds for ER4043 Aluminum Electrodes19Typical Melting Rates for Aluminum Electrodes20Typical Conditions for Short Circuit GMAW of Carbon and Low Alloy SteelMaterial ThicknessType of WeldWire DiameterCurrent Volt
38、age1Wire Feed SpeedShielding Gas2Gas Flowin. mm in. mm amps volts IPM mm/s CFM LPM.062 1.6 Butt3.035 0.9 95 18 150 64 75% Ar + 25% CO225 12.125 3.2 Butt3.035 0.9 140 20 250 106 75% Ar + 25% CO225 12.187 4.7 Butt3.035 0.9 150 20 265 112 75% Ar + 25% CO225 12.250 6.4 Butt3.035 0.9 150 21 265 112 75% A
39、r + 25% CO225 12.250 6.4 Butt4.045 1.1 200 22 250 106 75% Ar + 25% CO225 121. Direct current electrode positive.2. Welding grade CO2may also be used.3. Root opening of .03 in. (0.8 mm).4. Root opening of .062 in. (1.6 mm).21Typical Conditions for GMAW of Austenitic Stainless SteelUsing a Spray Arc i
40、n the Flat PositionMaterial ThicknessType of WeldWire DiameterCurrent Voltage1Wire Feed SpeedShielding GasGas Flowin. mm in. mm amps volts IPM mm/s CFM LPM.125 3.2 Butt Joint with Backing.062 1.6 225 24 130 55 98% Ar+ 2% O230 14.25026.4 V-butt Joint 60 Inc. Angle.062 1.6 275 26 175 74 98% Ar+ 2% O23
41、5 16.37529.5 V-butt Joint 60 Inc. Angle.062 1.6 300 28 240 102 98% Ar+ 2% O235 161. Direct current electrode positive.2. Two passes required.22Typical Conditions for GMAW of Austenitic Stainless SteelUsing a Short Circuiting ArcMaterial ThicknessType of WeldWire DiameterCurrent Voltage1Wire Feed Spe
42、edShielding GasGas Flowin. mm in. mm amps volts IPM mm/s CFM LPM.062 1.6 Butt Joint .030 0.8 85 21 185 78 90% He +7.5% Ar+2.5% CO230 14.093 2.4 Butt Joint .030 0.8 105 23 230 97 90% He +7.5% Ar+2.5% CO230 14.125 3.2 Butt Joint .030 0.8 125 24 280 118 90% He +7.5% Ar+2.5% CO230 141. Direct current el
43、ectrode positive.23Typical Conditions for GMAW of Aluminum in the Flat PositionMaterial ThicknessType of WeldWire DiameterCurrent Voltage1Wire Feed SpeedShielding GasGas Flowin. mm in. mm amps volts IPM mm/s CFM LPM.062 1.6 Butt .030 0.8 90 18 365 155 Argon 30 14.125 3.2 Butt .030 0.8 125 20 440 186
44、 Argon 30 14.187 4.8 Butt .045 1.1 160 23 275 116 Argon 35 16.250 6.4 Butt .045 1.1 205 24 335 142 Argon 35 16.375 9.5 Butt .063 1.6 240 26 215 91 Argon 40 191. Direct current electrode positive.24Consumable Welding WireInches per Pound of WireTo convert from inches per pound to mm per kg, multiply
45、by 11.52.Wire Diameter MaterialDecimal InchesFraction Inches Mag. Alum.Alum. Bronze (10)%Stainless SteelNi + Cr.MildSteelStainless Steel Str. ChromeSi.BronzeCopper Nickel NickelDe-ox. Copper.020 50,500 32,400 11,600 11,350 11,100 10,950 10,300 9,950 9,990 9,800.025 34,700 22,300 7,960 7,820 7.680 7,
46、550 7,100 6,850 6,820 6,750.030 1/32 22,400 14,420 5,150 5,050 4,960 4,880 4,600 4,430 4,400 4,360.035 16,500 10,600 3,780 3,720 3,650 3,590 3,380 3,260 3,240 3,200.040 12,600 8,120 2,900 2,840 2,790 2,750 2,580 2,490 2,480 2,450.045 3/64 9,990 6,410 2,290 2,240 2,210 2,170 2,040 1,970 1,960 1,940.0
47、62 1/16 5,270 3,382 1,220 1,180 1,160 1,140 1,070 1,040 1,030 1,020.078 5/64 3,300 2,120 ,756 ,742 ,730 718 ,675 ,650 ,647 ,640.093 3/32 2,350 1,510 ,538 ,528 ,519 510 ,480 ,462 ,460 ,455.125 1/8 1,280 ,825 ,295 ,289 ,284 279 ,263 ,253 ,252 ,249Melting rate (lbs/hr) = Melting rate (kg/hr) = wire fee
48、d speed (in/min) 60inches per pound of wire-wire feed speed (mm/min) 60mm per kg of wire-25FCAW Filler Metal Specifications and Classification SystemMaterialFiller MetalX Designator Description ExampleAWS Spec. AWS Class.*Steel, carbon A5.20 EXZT-Y Tensile strength 10,000 (psi) E71T-1Steel, low allo
49、y A5.29 EXZTY-Y Tensile strength 10,000 (psi) E80T5-Ni2Stainless steel A5.22 EXXXTZ-Y Stainless alloy (308, 410, etc.) E308LT1-1*LegendE Filler metal may be used as an electrodeT Filler metal is tubularZ Position usage0 Flat and horizontal positions1 All positionsY Designator (or combination of designators) for usab
