1. Amperage / Wire Feed Speed

Amperage should be the first question you ask before striking an arc.

In GMAW, amperage is directly tied to wire feed speed. It controls penetration and directly influences heat input

• More wire = more amperage
• More amperage = deeper penetration (in most cases)
• More amperage = more heat
• More wire = ability to travel faster.

Fusion creates the bond; penetration defines its depth. Together, they ensure a sound weld. But remember: higher heat doesn't automatically mean a better weld. Success in GMAW relies on balancing voltage and wire feed speed to get the penetration you need without overheating the joint

2. Voltage

Voltage controls how amperage transfers across the arc.

As voltage increases, your transfer mode changes.

Gas Metal Arc Welding (GMAW) has four primary transfer modes:

1. Short Circuit
2. Globular
3. Spray
4. Pulse

Short arc:

Lower voltage. Electrode touches the puddle. Good for thin material and out-of-position work. Can increase spatter if not tuned properly.

Globular:

Generally undesirable. High spatter, poor control, inconsistent fusion.

Spray:

Higher voltage and amperage. Fine droplets, low spatter, high deposition.

Pulse:

Controlled droplet transfer with lower overall heat input.

Quick guide:

• More voltage = wider arc (in spray)
• Less voltage = tighter arc (in short arc)

3. Shielding Gas

Shielding gas does more than protect the weld from the atmosphere.

It affects:

• Penetration depth
• Penetration profile
• Transfer mode
• Arc stability

There is no “one gas fits all.”

Examples:

• 75% Argon / 25% CO₂ will not achieve true spray or pulse transfer
• For spray and pulse, CO₂ typically needs to be 20% or less
• Not all aluminum welds require Helium. 100% Argon with proper settings can handle thicker materials – without added gas costs

Before adjusting machine settings, confirm your gas supports the transfer mode you’re trying to achieve.

4. Contact Tip to Work Distance (CTWD)

Contact tip to work distance (CTWD) directly affects amperage and arc behavior.

• Increase CTWD (move away from the arc) → Amperage decreases
• Decrease CTWD (move towards the arc) → Amperage increases
• Increasing CTWD preheats the wire before it enters the arc.
• Decreasing CTWD increases penetration – but that isn’t always the right fix.

Consistency is critical.

With Cobot Welder:

• Use the supplied 15mm Teach Tip for consistency
• Adjust CTWD in Beacon using ±10mm offset
• Maintain repeatable results across production runs

Inconsistent CTWD = inconsistent welds.

5. Travel Speed

Travel speed controls deposition and heat input. Essentially, the faster we travel the more we can get done.

Faster travel:

• Less heat input per inch
• Higher productivity

Manual travel speed averages:

• GMAW: 8-12 inches per minute
• GTAW: 6-8 inches per minute

With robotic welding:

• Beacon allows 1-90 inches per minute

If you’ve automated the weld, take advantage of it! Increase travel speed where penetration and fusion allow.

Productivity lives here.

6. Torch Angles

Torch angles are the link between proper weld settings and the soundness of a weld. In welding there are two torch angles to focus on.

Torch Angle (Work Angle)

Viewed from the side profile of our joint.

Most welds aim for 45° to evenly distribute weld material and achieve fusion in the root.

Torch Angle (Work Angle)

In some circumstances, the torch needs to favor one side of the joint or the other. The bottom base material is thicker than the top material, so the arc should favor the thicker material.

Push vs Pull (Travel Angle)

Push vs Pull (Travel Angle)

In GMAW:

• PUSH the weld
• Most codes allow 5 to 15° of push

In FCAW:

• PULL or DRAG the weld
• Most codes allow -5 to -15° of push

With Beacon Pro, angles can be:

• Adjusted by the degree
• Set relative to path direction
• Tuned in fixed or adaptive orientation

Precision here improves consistency across every part.

7. Electrodes

Electrode selection starts before the material hits the shop floor.

Consider:

• Base material
• Joint design
• Position
• Required strength
• Service environment

Wire diameter matters.

• Larger diameter wire allows more amperage
• More amperage allows better arc control
• Larger wire improves deposition efficiency

Since our cobot handles the welding, you can select wire based purely on performance rather than considering operator comfort or heat exposure.

Final thought

Every weld outcome is the result of variable control.

If something looks off:

• Don’t blame the machine
• Don’t blame the wire
• Don’t blame the gas

Check the variables.

Master these seven and you control penetration, profile, productivity, and quality.