If amperage measures the volume of electrons flowing through an electrical current, voltage measures the pressure that allows them to flow. The metal transfer mode typically transitions from globular to spray mode transfer above 190 amps of welding current for specific metal and shielding gas combinations. With the voltage and travel speed variables held constant, the increase in WFS and current indicates a substantially deeper weld moving from the 1st to the 5th.Īlso, note the fingerlike penetration in Welds 3-5 caused by the metal transfer mode in the welding arc changing to "spray metal" transfer mode. Notice the increase in weld penetration from Weld 1 to Weld 5. Table 1 shows the welding data from the following weldsįigure 1: Cross-Sectional View of Welds 1-5 (Table and Image Courtesy of EWI.org) The results are evident in Figure 1: Cross-Sectional View of Welds 1 through 5. You can see from the table that as the wire feed speed increased, so did the amperage. The primary way of adjusting the current is by changing the WFS. Keep in mind that the welding operator sets the WFS-not the current level-on a GMAW-CV power supply. As you can see, the WFS was incrementally increased from Weld 1 through Weld 5, which, in turn, increased the welding current. Take a look at Table 1: Welding Current Data to see how this works in practice. That's because as the welding current increases, the weld penetrates deeper into the base material.
If the WFS is set too high, it can lead to burn-through. WFS and current are directly related: as one increases, so does the other and vice versa. Wire feed speed (WFS), another of the welding variables, controls amperage and the amount of weld penetration. Amperage measures the strength of the electrical current, with its primary effect on welding being the melt-off rate of the electrode and the depth of penetration into the base material. The welding current is the variable that mainly controls the amount of weld metal deposited during the welding process. And since they are considered among the primary aspects that impact a GMAW weld, we will take a more detailed look at them.
Of all the welding factors, voltage and amperage cause the most confusion, especially in the novice welder. While many variables can influence a weld's quality, including the type and thickness of the base material, the four primary factors affecting it are welding current, welding voltage, contact-to-work distance, and travel speed. The heat from the electrical arc melts the base metal and the wire filler metal being fed into the weld pool. The molten weld pool is protected from the atmosphere by a shielding gas that flows around the wire filler metal in the weld pool and the weld pool itself. Gas metal arc welding (GMAW) is a welding process that happens when an electrical arc is established between a base material and a continuously fed wire electrode.
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