Gas Metal Arc Welding (GMAW) Overlay Cladding – The Ultimate FAQ Guide

GMAW weld overlay is one of the more common types in performing weld overlay. Because of its simplicity and effectiveness, it’s one of the techniques loved by many industrial companies.

In this guide, we will be walking you through the GMAW weld overlay process. We’ll talk about everything you need to know about it; what it is, how it can help you with your business, as well as the machines needed to complete the work.

What is GMAW?

It’s a short term for Gas Metal Arc Welding.

What is GMAW
Source: Weld Guru

It describes the process where an electrode is fed through the torch at a steady and controlled rate.

Simultaneously, you ought to apply shielding gas to the site or point of welding to avoid weakening the weld.

Is GMAW the Same as MIG?

MIG or Metal Inert Gas welding is actually a subset of GMAW.

MIG Welding

Source: American Torch Tip

The GMAW process can have different options for shielding. They are:

  • Using a Flux-Cored Wire
  • Gas Flowing Through the Torch

In MIG, on the other hand, it specifies the usage of inert gas (usually helium and argon). So, you can say that they’re the same in terms of process and the foundation.

However, they’re different in terms of the shielding procedure and selection.

What are GMAW Welding Machines?

GMAW welding machines are the equipment you can use to perform the GMAW process.

GMAW Welding Machines
Source: Sparkline Welders

In GMAW, you can choose from the four (4) different methods of metal transfer. They are:

  • Spray
  • Pulsed Spray
  • Globular
  • Short-Circuiting

What Does Weld Overlay Mean?

Weld overlay is the deposition of one or more metals to a specific part or product.

Weld Overlay

Source: Weartech International

The overall goal of weld overlay is to improve desirable properties of the base product. Moreover, it can also be used to restore the shape and the dimensions of the component.

Is GMAW Cladding Different From GMAW Weld Overlay?

Cladding and weld overlay are terms that are usually interchanged. They’re processes that are almost similar, but deep down, they’re different.

GMAW Weld Overlay
Source: Hi Tech Weld Overlay Group

GMAW cladding is a GMAW process that deposits material into the surface of a workpiece.

The goal is to coat the component to make it resistant against wear, corrosion, and abrasion.

GMAW weld overlay is a GMAW process that deposits material into the workpiece.

The goal is either to improve its properties or to restore its form, shape, or dimensions.

GMAW vs. FCAW Welding?

GMAW is a process that utilizes a solid wire electrode for its filler metal.

FCAW Welding

Source: Tulsa Welding School

FCAW is short for Flux-Cored Arc Welding. It is a process that has materials in the core that when burnt, produces shielding and fluxing agents.

What’s different between them is their consumables. In FCAW you use a flux-cored wire, which is what releases the shielding agent.

In GMAW, however, you use a solid consumable wire electrode for it.

GMAW vs. GTAW Welding?

GTAW is a term short for Gas Tungsten Arc Welding.

GTAW Welding
Source: Welding Certification Center

The main difference that it has with GMAW is that it uses a non-consumable tungsten electrode; whereas GMAW uses a consumable wire electrode.

You can perform them in the same way, you just have a different electrode to use.

What is GMAW Cladding?

GMAW cladding uses the GMAW method to deposit materials to a surface or a workpiece.

GMAW Cladding
Source: Mechanical Industry Steel Products

The goal is to create materials that are better, stronger, and more durable; materials that are:

  • Corrosion-Resistant
  • Higher Impact Tolerance
  • Higher Temperature Tolerance
  • Abrasion-Resistant
  • Wear-Resistant
  • And So On

Benefits of GMAW Overlay Cladding?

In comparison to other welding techniques, GMAW cladding can give you the following benefits:

GMAW Overlay Cladding Benefits
Source: American Welding Society

  • Lower fumes, which creates a better sight of the project
  • Can be used for a wide range of alloys and metals
  • Does not require operator to be highly skilled
  • Higher productivity because it can be fully automatic
  • Has higher electrode efficiencies

These are just some of the benefits that the GMAW weld overlay process can give you.

Where Can a GMAW Weld Overlay Process be Best Applied To?

GMAW Weld Overlay Applications
Source: Synergy Additive Manufacturing

The general application of GMAW weld overlay would be in the following sectors:

  • Chemical Plant Industry
  • Paper Industries
  • Naval Equipment Industry
  • Power Plant Industry
  • Oil & Gas Industry

So, if you are engaged in any of these sectors, you can benefit well from it. You will have no doubts about it.

What is a GMAW Weld Overlay For?

It’s the same as why you would want to get a weld overlay – to improve properties.

Weld Overlay GMAW
Source: Research Gate

What separates it from the rest would be the ease of how it’s operated and the availability.

What Materials Can You Weld With GMAW Weld Overlay?

All of the most important metals can be welded using the GMAW weld overlay process.

Materials You Can Weld
Source: Sambhav Metal & Alloys

Here are some of the things included in the list:

  • Titanium
  • Nickel Alloys
  • Copper
  • Stainless Steel
  • Aluminum Steel
  • And Many More

TIP: One BIG advantage that GMAW has is its ability to weld many alloys and metals. It’s flexible, versatile, and it’s not that demanding.

Does GMAW Weld Overlay Produce Slag?

GMAW uses a metal electrode for the shielding. Flux is one of the main agents that create slag.

Welding Slag
Source: Family Woodworking

But since you wouldn’t be using flux in GMAW, you can expect no slag.

Where You Can Get GMAW Weld Overlay Service?

There wouldn’t be a shortage of companies that can help you with a GMAW weld overlay.

In fact, many have already adapted to it. However, if you’re looking for the best and the highest quality, you can work with us here at Waldun.

Waldun has been the leading GMAW weld overlay company in China. Amassing thousands of clients who trust us, you can’t go wrong.

The next project where you’ll need the GMAW weld overlay cladding process, work with us! Experience high quality procedures without spending a fortune for it!

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