Gas
metal arc welding (GMAW), sometimes referred to by
its subtypes metal inert gas (MIG) welding or
metal active gas (MAG) welding, is a semi-automatic
or automatic arc welding process in which a continuous
and consumable wire electrode and a shielding gas are
fed through a welding gun. A constant voltage, direct
current power source is most commonly used with GMAW,
but constant current systems, as well as alternating
current, can be used. There are four primary methods of
metal transfer in GMAW, called globular,
short-circuiting, spray, and pulsed-spray, each of which
has distinct properties and corresponding advantages and
limitations.
Originally developed for welding aluminium and other non-ferrous
materials in the 1940s, GMAW was soon applied to steels because it
allowed for lower welding time compared to other welding processes.
The cost of inert gas limited its use in steels until several years
later, when the use of semi-inert gases such as carbon dioxide
became common. Further developments during the 1950s and 1960s gave
the process more versatility and as a result, it became a highly
used industrial process. Today, GMAW is the most common industrial
welding process, preferred for its versatility, speed and the
relative ease of adapting the process to robotic automation. The
automobile industry in particular uses GMAW welding almost
exclusively. Unlike welding processes that do not employ a shielding
gas, such as shielded metal arc welding, it is rarely used outdoors
or in other areas of air volatility. A related process, flux cored
arc welding, often does not utilize a shielding gas, instead
employing a hollow electrode wire that is filled with flux on the
inside.