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Welding Process Parameters & Method Selection Guide
Practical guide to selecting and parameterizing welding processes SMAW, GMAW, SAW, and GTAW for hot forging applications.
Shielded Metal Arc Welding (SMAW)
SMAW (stick welding) is widely used for repair welding of forging dies and tooling. For die steel repair, use E8018-B2 electrodes with preheat of 300-400°C, interpass temperature maintained at 350°C max, followed by slow cooling in dry sand or furnace. Current range for 4mm electrode: 140-190A (AC or DC+).
Gas Metal Arc Welding (GMAW/MIG)
GMAW offers higher productivity for structural welding of press frames and heavy equipment. Use ER70S-6 wire with 75% Ar/25% CO2 shielding gas. Typical parameters for 1.2mm wire in flat position: 220-280A, 24-28V, wire feed speed 8-12 m/min.
| Process | Application | Current Range | Deposition Rate |
|---|---|---|---|
| SMAW | Die repair, general fab | 100-300A | 1-3 kg/h |
| GMAW | Structural, plate welding | 150-350A | 3-8 kg/h |
| SAW | Heavy plate, longitudinal seams | 300-1000A | 5-20 kg/h |
| GTAW | Root pass, thin sections | 50-250A | 0.5-2 kg/h |
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