CHAPTER 1: INTRODUCTION
1.1 Overview of Fusion Welding
Fusion welding is a family of joining processes that melts and coalesces materials by heating them to
their melting point. The fusion welding family includes gas metal arc welding (GMAW), gas tungsten
arc welding (GTAW), shielded metal arc welding (SMAW), flux-cored arc welding (FCAW), and
submerged arc welding (SAW). These processes differ in how the heat is applied and how the weld
pool is protected from atmospheric contamination.
The fundamental requirement for fusion welding is sufficient heat to melt the base metal and filler
material (if used). In arc welding processes, this heat is generated by an electric arc—a sustained
electrical discharge between an electrode and the workpiece. The arc temperature can reach 6,500°C
to 20,000°C, far exceeding the melting point of common metals.
1.2 Definition of GMAW
According to AWS A3.0, Standard Welding Terms and Definitions, Gas Metal Arc Welding (GMAW) is
defined as: "An arc welding process that uses an arc between a continuous filler metal electrode and
the weld pool. The process is used with shielding from an externally supplied gas and without the
application of pressure."
Key characteristics of GMAW include:
☛ Continuous wire electrode fed automatically through the welding gun
☛ Electric arc provides heat for melting
☛ Consumable electrode serves as filler metal
☛ External shielding gas protects the weld pool
☛ No flux coating on electrode (unlike SMAW)
☛ Can be semi-automatic, automatic, or robotic
☛ Direct current electrode positive (DCEP) is standard polarity
1.3 Terminology (MIG vs MAG)
The terminology for GMAW varies internationally, leading to some confusion:
MIG (Metal Inert Gas) Welding:
☛ Original term developed when inert gases (argon, helium) were used
☛ Technically correct only when using 100% inert shielding gases
☛ Common in North America and worldwide for all GMAW applications
☛ Applied to aluminum, magnesium, copper, nickel alloys with argon/helium
☛ Term persists even when active gases are used
MAG (Metal Active Gas) Welding:
☛ European terminology (ISO 857-1)
☛ Used when active/reactive gases are employed (CO₂, CO₂ mixtures)
☛ Technically more accurate for steel welding with CO₂-based gases
☛ Common in Europe, less so in North America
☛ Applied to carbon steel and low-alloy steel welding
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In practice, "MIG welding" is used colloquially to refer to all GMAW processes regardless of shielding
gas. The technically correct term according to AWS is simply GMAW, which encompasses both inert
and active gas applications.
1.4 Historical Development
The development of GMAW represents a significant milestone in welding technology evolution:
Early Arc Welding (1800s-1930s):
☛ 1800: Humphry Davy discovers electric arc phenomenon
☛ 1881: French scientist Auguste de Méritens patents first arc welding process
☛ 1890s: Carbon arc welding developed
☛ 1920s: SMAW (stick welding) becomes commercialized
☛ Limitation: Batch process requiring frequent electrode changes
GMAW Development (1940s):
☛ 1948: Battelle Memorial Institute develops GMAW process
☛ Initial application: Welding aluminum and magnesium for aircraft
☛ Used argon shielding gas (expensive, limited steel application)
☛ Required DC power source with constant voltage characteristic
☛ Continuous wire feed mechanism was revolutionary
☛ Process called "Sigma welding" initially
Commercial Expansion (1950s):
☛ 1953: Lyubavskii and Novoshilov (USSR) introduce CO₂ shielding
☛ CO₂ made GMAW economically viable for steel welding
☛ Short-circuit transfer mode developed for thin materials
☛ Process gains acceptance in automotive and shipbuilding
☛ Equipment reliability improves with solid-state controls
Modern Era (1960s-Present):
☛ 1960s: Gas mixtures optimize transfer modes and penetration
☛ 1970s: Synergic control systems introduced
☛ 1980s: Pulsed GMAW commercialized for better control
☛ 1990s: Digital inverter technology reduces equipment size/weight
☛ 2000s: Waveform control for optimized metal transfer
☛ 2010s: Advanced robotics and real-time monitoring systems
☛ 2020s: AI-assisted parameter optimization and quality control
1.5 Industrial Applications
GMAW has become the most widely used arc welding process globally due to its versatility,
productivity, and quality. Major industrial applications include:
INDUSTRY APPLICATIONS MATERIALS
Automotive Body assembly, chassis, exhaust, components Mild steel, HSLA, Al alloys
Shipbuilding Hull fabrication, bulkheads, piping Mild steel, marine-grade steel
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Aerospace Airframe, fuel tanks, engine mounts Al alloys, Ti alloys, Ni alloys
Construction Structural steel, bridges, buildings Structural steel, rebar
Pipeline Cross-country pipelines, distribution API grade steels
Pressure Vessels Tanks, boilers, heat exchangers Carbon steel, stainless steel
Rail Transport Rail cars, locomotives, trackwork Structural steel, wear plates
Heavy Equipment Mining, construction, agricultural Thick plate, wear-resistant
Manufacturing Machinery, equipment, tooling Various ferrous/non-ferrous
Energy Wind turbines, solar frames, nuclear HSLA, stainless, special alloys
The global GMAW equipment and consumables market exceeds $5 billion annually, with growth driven
by automation, infrastructure development, and lightweighting trends in transportation.
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Comprehensive Assessment Test
1. What does GMAW stand for?
A) Gas Metal Arc Welding
B) Gas Manual Arc Welding
C) General Metal Arc Welding
D) Guided Metal Arc Welding
2. Who discovered the electric arc phenomenon that led to arc welding?
A) Thomas Edison
B) Humphry Davy
C) Nikola Tesla
D) Michael Faraday
3. In which year was the GMAW process developed?
A) 1938
B) 1948
C) 1958
D) 1968
4. Which organization developed the GMAW process?
A) MIT
B) Battelle Memorial Institute
C) Lincoln Electric
D) AWS
5. What does MIG stand for in welding terminology?
A) Metal Inert Gas
B) Manual Inert Gas
C) Metal Internal Gas
D) Machine Inert Gas
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6. What does MAG stand for in European welding terminology?
A) Metal Arc Gas
B) Metal Active Gas
C) Manual Active Gas
D) Machine Arc Gas
7. What was the initial application of GMAW when developed in 1948?
A) Steel fabrication
B) Aluminum and magnesium for aircraft
C) Copper welding
D) Stainless steel
8. Who introduced CO₂ shielding for GMAW in 1953?
A) American researchers
B) German scientists
C) Lyubavskii and Novoshilov (USSR)
D) Japanese engineers
9. What percentage of all welds are fillet welds?
A) 30-40%
B) 40-50%
C) 50-60%
D) 60-70%
10. What is the approximate arc temperature in GMAW?
A) 1,000-3,000°C
B) 3,000-5,000°C
C) 6,500-20,000°C
D) 25,000-30,000°C
11. Which shielding gas made GMAW economically viable for steel welding?
A) Argon
B) Helium
C) Carbon dioxide (CO₂)
D) Nitrogen
12. What is the most widely used arc welding process globally today?
A) SMAW
B) GTAW
C) GMAW
D) SAW
13. In GMAW, what serves as the filler metal?
A) Separate rod
B) Flux coating
C) Consumable wire electrode
D) Base metal only
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14. What protects the weld pool in GMAW from atmospheric contamination?
A) Flux coating
B) Slag layer
C) External shielding gas
D) Vacuum chamber
15. What is the global GMAW equipment and consumables market value annually?
A) Over $1 billion
B) Over $3 billion
C) Over $5 billion
D) Over $10 billion
Answers
1. A 2. B 3. B 4. B 5. A 6. B 7. B 8. C
9. D 10. C 11. C 12. C 13. C 14. C 15. C
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