Welder’s

Handbook
For Gas Shielded Arc Welding, Oxy Fuel Cutting & Plasma Cutting

Published by:
Air Products PLC

Designed and produced by:

PDF Conceptual Design & Marketing

Copyright:
Air Products PLC 1999 – 3rd Edition
Air Products Welder’s Handbook CONTENTS

Introduction

Fusion welding 2

Why use welding? 3

Arc welding processes 4

Welding terms 5

MIG/MAG welding 6

TIG welding 10

Plasma welding 17

Welding sheet 18

Welding plate 20

Welding pipes 22

Defects in welds 24

The right gas:

MIG/MAG welding 26

TIG welding 29

Welding data:

MIG/MAG welding 30

Flux cored electrodes 33

TIG welding 34

Oxy-fuel gas cutting 37

Plasma cutting 44

Safety always 46

Conversion data inside back cover

1
 Air Products Welder’s Handbook

Fusion welding 'T' joint

The most widely used welding proc-

esses rely on fusion of the components fillet
at the joint line. weld

In fusion welding, a heat source melts

the metal to form a bridge between the
components.

Two widely used heat sources are:

electrode
high current
low voltage Butt joint butt
supply weld
arc

Electric arc

fuel gas flame

blowpipe

air must be excluded

from heated area

Gas flame

The molten metal must be protected

from the atmosphere - absorption of
oxygen and nitrogen leads to a poor
quality weld.

Air in the weld area can be replaced by

a gas which does not contaminate the
metal, or the weld can be covered with
a flux.

2
 INTRODUCTION

Why use welding? Which process?

Welding is used because it is: A large number of welding processes

and techniques are available. No
● one of the most cost-effective process is universally best. Each has
methods of joining metal its own special attributes and must be
components matched to the application.
● suitable for thicknesses ranging
Choosing the most suitable process
from fractions of a millimetre to a
requires consideration of a number of
third of a metre
factors.
● versatile, being applicable to a
wide range of component
shapes and sizes

The joints produced by welding are: Factors in choosing

● permanent welding process:
● strong, usually matching the
strength of the components, ● type of metal
● leak tight, ● type of joint
● reproducible, ● production constraints
● readily inspected by non- ● equipment availability
destructive techniques.
● labour availability

Welding can be used: ● health, safety and the

environment
● in the workshop
● costs of consumables
● on site
● labour costs
for
● material thickness
● sheet
● plate
● pipe
● sections

3
Air Products Welder’s Handbook ARC WELDING

Arc welding processes Two of the most important processes

use a gas shield to protect the weld
metal from atmospheric
Fabrications involving sheet metal,
contamination.
plate or pipes are commonly welded
by an arc process.

4
 WELDING TERMS

Terms commonly used in filler metal Metal added to the weld

pool during welding. For TIG it is
gas shielded welding supplied as cut lengths of wire.
interpass temperature The
arc length Distance between the tip
temperature of the material adjacent to
of the electrode and the surface of the
the joint between each run is the
weld pool.
interpass temperature. In some
base metal Incorrectly used to applications, a maximum temperature
describe the metal from which the is specified to avoid metallurgical
components of the joint are made. changes in the metal.
The correct term is parent metal. melt run Melting the parent metal
bead A single run of weld metal by passing a TIG arc along the
deposited onto the surface of the surface. Filler metal is not used.
parent metal. nozzle In TIG and MIG/MAG
burn-off rate The rate at which the welding - A metal or ceramic tube
wire is melted. Quoted as a linear which confines the shielding gas to
measurement - m/min (metres per the weld area.
minute) or in/min. parent metal The metal which is to
deposited metal Material which is be joined by welding. Often incorrectly
added, either from the electrode or called the base metal.
filler wire, to build up the weld profile. pass or run The metal deposited
during one traverse of the joint by an
deposition rate The rate at which
arc. In TIG welding without a filler, the
melted electrode metal is added to the
term melt run may be more correct.
weld pool. Quoted in kg/hr (kilograms
per hour). Sometimes incorrectly preheat temperature The
temperature of the parent metal just
used in reference to the ratio of metal before welding is started. With some
deposited to the amount of electrode metals the parent metal is heated
melted - this is the deposition before
efficiency. welding to avoid problems such as
cracking or lack of fusion.
electrode The flux coated rod in
manual metal arc welding, the root run The first run deposited in a
tungsten in TIG and plasma welding joint where further runs are needed to
and the consumable wire in MIG/MAG fill the groove.
welding. The arc is formed between sealing run A run of weld metal
the parent metal and one end of the deposited on the reverse side of a butt
electrode. joint, along the line of the root.

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Air Products Welder’s Handbook

MIG/MAG welding principles The shielding gas can be:

● pure argon
Gas shielded metal arc welding is a
● argon mixed with small
semi-automatic process which is
amounts of other gases
suitable for both manual and
mechanised operation. ● helium or
● carbon dioxide
It is known by a variety of names:
according to the metal being welded.
● MIG - Metal Inert Gas
● MAG - Metal Active Gas
See pages 9 and 26.
● CO2 - carbon dioxide

A low voltage (18–40V), high current

(60–500A) arc between the end of a
wire electrode and the work provides
the heat needed for the welding nozzle to plate
distance-kept at
operation. The arc and the weld are about 19-25mm
protected from atmospheric
contamination by a gas shield.

drive rolls keep constant

wire feed speed arc length
spool of wire

power
supply unit
keeps arc
work length
constant gas nozzle

shielding gas

6
 MIG/MAG WELDING

Operation overhead

An electric motor feeds the wire into

the arc and the power source keeps
the arc length at a preset value leaving
the welder to concentrate on ensuring
complete fusion of the joint.
Power sources for MIG/MAG are
called constant voltage or potential, vertical
known as the self adjusting arc, and
constant current, known as controlled
arc or drooping characteristic units.
Modern power sources combine The appropriate technique for these
constant current and constant voltage types of joint is either ‘Dip Transfer’ or
(cc/cv) and are called inverters. ‘Pulse Transfer’.
These two techniques are also used
for welding sheet material.
Synergic MIG/MAG is an advanced
welding system which incorporates
both spray and pulse transfer.
Optimum conditions can be
established for a range of applications
which are readily reproduced by the
welder.
Special equipment is required for
Synergic-MIG/MAG welding.
joints in flat position
Welding data for MIG/MAG applica-
The process can be operated at tions are given on pages 30 to 33.
currents within the range 280–500A for
welding plates, thick walled pipes and
sections in the flat position. The term
‘Spray Transfer’ is used to describe
this type of operation.
❛ MIG/MAG welding with a
Ferromaxx™gas shield gives a low
Welds which are located in positions hydrogen content in the weld. This
where the metal tends to run out of the
means that lower preheat levels are
joint under the action of gravity are
welded at lower currents (60/180A). needed than with MMA welding. ❜

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Air Products Welder’s Handbook

Using MIG/MAG welding Voltage controls the profile of the

weld. Inductance (in Dip Transfer)
stabilises the arc and minimises
With MIG/MAG, the wire is pointed in
spatter. Wire feed speed sets the
the direction of travel (forehand
welding current.
technique). This allows the arc to fuse
the parent metal ahead of the weld
pool and gives the best penetration.
voltage
The welder controls the speed of travel high
to ensure that the weld pool does not correct
run ahead of the arc as this would low
cause lack of fusion.

Weld quality in MIG/MAG welding is

critically dependent on the skill of the
welder and selection of the welding
variables.
0

0 -8
0 Current controls:
75
● heat input
● size of weld
● depth of penetration

Wire diameter depends on the current

required. The table gives a guide to
the selection of wire diameter but the
exact relationship depends on the
material and the shielding gas.

Current Wire feed

450 - 550
Diameter range speed
(mm) (A) (m/min)

0.6 40–100 2–5

0.8 40–150 3–6
1.0 100–280 3–12
1.2 120–350 4–18

8
 MIG/MAG WELDING

Flux cored wires

flux
Wires for MIG/MAG welding are
usually solid. For carbon, carbon-
manganese, high strength low alloy
steels and stainless steels, joint
flux cored wires can be used. These
offer the advantages of higher welding
speeds and easier control of fillet
weld profiles.

cross section of flux cored wires

Air Products gases for
MIG/MAG welding
Ferromaxx™ Plus is the multi-purpose
Air Products welding gases enable the gas for welding carbon, carbon-
optimum results to be obtained with manganese, high strength low alloy
MIG/MAG welding of a range of steels and coated steels of all
metals. thickness’ with solid wires in dip, spray
and pulse transfer and with metal and
Pure argon is particularly effective for flux cored wires.
welding aluminium and its alloys. Also
used for copper and nickel. Inomaxx™ is a range of gases
specially designed for MAG and Pulse
Ferromaxx™ is a range of selected MAG welding stainless steels.
mixtures of argon, carbon dioxide and Inomaxx™ 2 is recommended for
other gases to provide ideal arc welding ferritic and austenitic grades
conditions for spatter free welding of of stainless steel of all thicknesses in
steels. Ferromaxx™ 7 is recommend- dip, spray and pulse transfer modes.
ed for carbon, carbon-manganese and
high strength low alloy steels up to
10mm thick in dip, spray and pulse
transfer modes. Ferromaxx™ 15 is the
choice for welding carbon, carbon-
manganese, high strength low alloy ❛ Faster travel speeds with Ferro-
steels and coated steels in dip, spray
maxx™, Inomaxx™ and Alumaxx™
and pulse transfer modes for all
mean reduced welding costs. ❜
thickness’.

9
Air Products Welder’s Handbook

Inomaxx™ Plus is the choice for

welding all thickness’ of ferritic and
austenitic stainless steels in dip, spray
and pulse transfer and with metal
cored wires.

Alumaxx™ Plus is the high perform-

ance argon - helium shielding gas for
MIG welding aluminium and it’s alloys
of all thickness’ in spray and pulse
transfer modes (Alumaxx™ Plus is also
the recommended gas for TIG welding
aluminium and copper).

See pages 26–28 for choosing the right

gas.

Tungsten inert gas welding

Principles
Tungsten inert gas shielded welding is tungsten
usually called TIG welding. It uses an electrode
arc between a tungsten electrode and
the work to fuse the joint. The
electrode is not melted and any filler
metal needed to build up the weld
profile is added separately.

Both the molten metal in the weld

pool, the tip of the filler wire and the weld pool
hot electrode are protected from
atmospheric contamination by a shield
of inert gas. Usually the gas is argon,
but helium by itself or mixed with
argon may be used for special ❛ Air Products gases containing
applications. Argon - hydrogen mix- helium give better penetration on
tures can be used for stainless steel. metals with high thermal conduc-
tivity. ❜
See page 29.

10
 TIG WELDING

Operation Using an arc starting device enables

the arc to be struck without touching
the electrode to the work.
TIG welding is suitable for both manual
and mechanised welding.

In manual welding, the operator points

the electrode in the direction of
welding and uses the arc to melt the
metal at the joint.

If filler metal is required, for example

when making a fillet weld, it is added
to the leading edge of the weld pool.

Filler is supplied as cut lengths of wire

- usually 1 metre long.
Choice of current
Arc length is controlled by the welder Both direct current (dc) and
and is usually between 2mm and alternating current (ac) can be used
5mm. with TIG welding.
Heat input to the arc depends on the Direct current with the electrode
current chosen by the operator. connected to the negative terminal
Travel speed is adjusted to match the of the power source is used for:
time needed to melt the joint. ● carbon steels
● copper and its alloys
● stainless steels
● nickel and its alloys
● titanium and its alloys
● zirconium and its alloys
Alternating current is used for
welding:
2–5mm
● aluminium and its alloys
● magnesium and its alloys
● aluminium bronze

11
Air Products Welder’s Handbook

Power sources for TIG Crater filling

Automatic gradual reduction of the
current at the end of a weld run avoids
Power sources for use with TIG
the formation of a crater.
welding must be capable of delivering
a constant current at a preset value.

welding current
They are often called ‘drooping
characteristic’ units. arc extinguished

Rectifier units are commonly used for

dc welding although motor generators
may be more suitable for site use. time
Single phase transformer units are
almost universally used for welding
aluminium. Modern power sources crater
crater or
ofhole
holeatat
have square waveform. end
end of
of weld
weld
welding current

Combined ac/dc power sources can

be used where there is a mix of work.
current
reduced in
Modern power sources combine steps
constant current and constant voltage
(cc/cv) and are called inverters.

The power source should be

weld surface
equipped with: smooth at end of
weld run
● foot operated on/off switch
● remote control for the current
● crater filling device
● an arc starting device
● gas control valves
● water control valves - for nozzle
cooling at high currents.
❛ Use stainless steel wire brushes
and wire wool to clean aluminium
Welding data for TIG applications are
given on pages 34 to 36. before welding.❜

12
 TIG WELDING

Electrodes for TIG welding Before use, the end of the electrode is
ground on a silicon carbide wheel to
give the most appropriate profile.
Pure tungsten electrodes can be used
Contamination with other metals must
for TIG welding. Thoriated and
be avoided as this lowers the melting
zirconiated types give easier starting
point of the electrode.
and better arc stability and are
generally preferred. For dc welding a sharp point is
required.
Thoriated tungsten electrodes contain
2% thoria (thorium oxide) and are used For ac welding only a small bevel is
for dc welding. needed as the end of the electrode
becomes rounded when the arc is
Zirconiated tungsten electrodes
operated.
contain 2% zirconia (zirconium oxide)
and are recommended for ac welding
of aluminium.
The diameter of the electrode is
chosen to match the current. The
minimum current depends on arc
stability.
The maximum current a given
diameter of electrode can carry is
determined by the onset of over-
heating and melting.

Maximum operating current

Electrode
diameter

(A)
mm

Direct Current Alternating

(dc) Current (ac)

1.6 60–150 60–125

2.4 170–250 120–210
3.2 225–330 150–250
4.0 350–480 240–350 ❛ Do not completely empty a
cylinder of gas. Always close the
4.8 500–675 330–460
valve before returning a used
Taken from BS EN26848:1991 cylinder to the stores. ❜

13
Air Products Welder’s Handbook

Torches for TIG welding A gas lens can be used to stabilise the
gas shield. With this, the electrode can
project further from the end of the
TIG torches are rated according to the
nozzle, giving better visibility of the arc
current they can carry without
overheating. At currents above 150A and the weld pool.
the torch body and possibly the nozzle
are water cooled. torch body

At lower currents, the flow of shielding

gas provides sufficient cooling. ceramic
nozzle
An advantage of the TIG process is the gas gas
availability of a range of torches which gas lens
enable welds to be made even on
small components.

The efficiency of the gas shield is tungsten

electrode
critically dependent on the design of
the nozzle. uniform laminar gas flow

Gases for TIG welding

Pure argon Suitable for all metals.

Alumaxx™ Plus. An argon-helium
mixture which allows faster welding
penciltorch
pencil torch and deeper penetration on aluminium
and its alloys and copper and its
alloys.
Inomaxx™ TIG. An argon - helium -
hydrogen mixture which gives lower
ozone emissions, less surface
oxidation, improves the weld profile,
welding speed and penetration on
stainless steel, cupro-nickel and nickel
swivel
swivelhead
headtorch
torch alloys.
See page 29 for choosing the right gas.

14
 TIG WELDING

Pulsed TIG

At low currents, a TIG arc becomes

difficult to control. Pulsing the current
gives stable operation at low heat
input levels.
weld
consists
The arc is operated at a low current of overlapping
onto which pulses of high current are circular weld pools
superimposed. The frequency of the
pulses and their duration are set by direction of
welding
the operator to the required heat input
and degree of weld pool control.

Conventional torches are used but the

power source must be either specially
designed for Pulsed TIG or in older
equipment supplemented by an B A
adaptor which supplies the pulses.

pulse duration
high level
pulse

conventional TIG - welding speed

progressively increased from A-B
pulse height

pulsed TIG - constant travel speed

current amps

mean
pulse

Pulsed TIG is particularly suited to the

welding of sheet less than 1mm thick
low level

as it reduces the risk of burn through.

time pulse

Pulsed TIG is also used to weld

cylindrical components as it avoids the
need to increase travel speed to keep
waveform for pulsed TIG welding the weld width uniform. This is of great
advantage in mechanised welding.

15
Air Products Welder’s Handbook

TIG spot welding Gas backing

TIG spot welding provides an When the weld metal penetrates

alternative to resistance spot welding through the root in a butt joint, it is
where access is from one side only or exposed to air and may become
it is not possible to fit the component oxidised. This is not normally a
between the arms of the spot welder. problem with aluminium and its alloys,
but can cause poor quality welds in
In this technique, the electrode is held steels, especially stainless steel and
at a fixed distance above the surface of reactive metals (such as titanium).
a lap joint. The arc melts a circular Contamination can be avoided by
weld pool which penetrates through providing a gas backing.
the interface between the sheets. After
a pre-determined time, usually from
0.4 to 1 second, the current
is reduced progressively to allow the
clamp joint clamp
weld to solidify without a crater. line

work
nozzle placed piece
in contact sheet
to give correct copper backing argon flows through
arc length bar with holes at holes to protect
5mm intervals underside of weld

Removable plugs or dams in a pipe

confine argon to weld areas

TIG spot welding is not

recommended for aluminium

16
 TIG WELDING

Plasma arc welding Plasma arc welding relies on a special

technique known as keyholing. First a
hole is pierced through the joint by the
The arc used in TIG welding can be
converted to a high energy jet by plasma arc. As the torch is moved
forcing it through a small hole in a along the joint, metal melts at the front
of the hole, swirls to the back and
nozzle. This constricts the arc and
forms the plasma jet. solidifies.

plasma tungsten
gas electrode

shielding
gas

work piece arc plasma jet

Plasma arc welding is mainly used for

butt joints in plates and pipes. Its
principal advantage is that it gives
controlled penetration.

keyhole
The gas surrounding the electrode is
usually argon. Either argon or an
argon-hydrogen mixture can be used
for the shielding gas.

The plasma arc process is also used

direction of weld for cutting.

See page 44.

17
Air Products Welder’s Handbook

TIG and MIG/MAG

'T' joint
welding of sheet

Both TIG and MIG/MAG processes

can be used to weld sheet material.
With MIG/MAG, dip or pulse transfer
techniques must be used.

Corner joint

no gap

The edges of the sheet are cut square,

with no burrs.
Butt joint

gap not
greater than half sheet thickness
Butt joints in sheet less than 1mm
thick are TIG welded. The edges of the
sheet can be flanged to avoid the The gap between the edges depends
need to use filler metal. on the joint type and sheet thickness.

18
 WELDING SHEET METAL

The sheets must be held in alignment, Control of the angle between the gun
preferably by clamping against a and the surface of the sheet is critical
backing bar. in MIG/MAG welding.
0
0
0 -8
75

copper
backing bar

450 - 550

If this is not possible, tack welds

about 10mm long should be placed at
50mm intervals. The tacks are melted
into the main weld.

mm
10 mm
50

o _ 80
75

See page 31 for welding conditions.

19
Air Products Welder’s Handbook

MIG/MAG welding of plate

Spray transfer can be used for butt
joints in the flat position and for
T-joints in both flat, horizontal and
vertical positions. All vertical and
overhead welding needs a low current
technique — dip or pulse transfer.
Single 'V'
Up to 3mm thickness, the edges of the
plate can be cut square.

A single or double bevel is used for

greater thicknesses.

The dimensions of the edge

preparation depend on thickness and
type of material.

Double 'V'

Low carbon steel

Type Thickness Aluminium
and stainless steel
Square edge

t Up to 6mm g = 1/2t g = 1/2t

g
Single V
A Rf
6mm A = 60° A = 65-70°
to Rf = 1.5mm max Rf = 1.5mm max
g
18mm g = 1mm max g = 1.5mm max
Double V
Above A = 50° A = 80-90°
A Rf
18mm Rf = 1 to 2mm Rf = 1.5mm max
g = nil g = 1.0mm max

20
 WELDING PLATES

The number of runs needed to fill the Alternatively, the underside of the root
groove depends on the thickness. run can be supported by a backing bar
which is removed after welding or a
backing strip which is left in place.

filling passes capping pass

tack weld to hold backing strip

root run

The deep penetration characteristic of root run

root-run
spray transfer makes it difficult to fixed into
fixed into
control the molten metal in a root run. backing strip
backing strip
The root run can be deposited with dip,
or MMA welding can be used.
See page 32 and 33 for welding
conditions.

root-run supported
by groove in
bar

❛Improved metal transfer with

argon based gases, as compared
to pure carbon dioxide, makes root
copper
backing bar run control easier. ❜

21
Air Products Welder’s Handbook

Pipe and tube joints roller manipulator

There are three main types of welded

joint used in pipework.
● butt
● branch
● flange

one driven unit and one idler

flat

butt
vertical

branch overhead

Before welding, the pipes can be

clamped or tack welded to maintain
alignment.
flange
leading and trailing
If possible, during welding the pipe edges, tack welded and
ground
should be rotated so that the weld is
made in the horizontal position - use
spray, dip or pulse transfer for MIG/
MAG.

If the weld must be made in a fixed

position and changes from flat to
vertical to overhead as the weld
progresses round the joint - use dip or
pulse transfer for MIG/MAG. tack weld

22
 WELDING PIPES

Root runs can be made by TIG or MIG/ Flange joints are either fillet or butt
MAG with dip or pulse techniques or welded.
by MMA welding. With TIG welding the
bore of the pipe can be filled with
argon or nitrogen to protect the
penetration bead and to control its
profile.

Unbacked butt joint

uniform root gap

fillet butt
The edge preparation is chosen to suit
the process.

For ease of welding flanges, the axis of

Backed butt joint
the pipe should be vertical and the
flange rotated.

backing strip

❛ Protect the underside of the weld

with Air Products argon or nitrogen
See page 16 ❜ flange rotated

23
Air Products Welder’s Handbook

Defects in welds Lack of fusion

● arc length too short
Porosity
● current too low
● gas flow too high
● travel speed too slow in MAG
● blocked nozzle welding
● draughty conditions ● incorrect inductance setting
(MAG)
● moisture on work or filler
● paint or grease on surface of
metal

A
A
B
B

A-lack of inter-run fusion

B-lack of side fusion

Lack of penetration
Undercut
● current too low
● travel speed too high
● root gap too small
● current too high
● root face too thick
● poor technique
● poor technique
● misaligned joint

24
 WELDING DEFECTS

Spatter Tungsten inclusions

● insufficient inductance (MAG) TIG welding
● short arc length ● electrode tip touching weld
pool
● voltage too low (MAG)
● current too high for electrode
● rusty plate
diameter
● using thoriated electrode for ac

Centre line crack

● low voltage, high current
● high sulphur in steel
● incorrect filler
(stainless steel and aluminium)
● incorrect use of preheat
● high restraint

❛ Acceptance levels for defects are

given in British Standards. Check
the Standards before you start to
weld. ❜

25
Air Products Welder’s Handbook

Gases for MIG/MAG welding ● Ferromaxx™ gases give a

smoother weld surface.
Carbon , carbon-manganese and ● Steel which contains chromium
high strength low alloy steels needs special consideration.
Ferromaxx™ 7, Ferromaxx™ 15, There is a danger that carbon
Ferromaxx™ Plus and carbon dioxide dioxide in the gas will react with
(CO2) are used to weld these steels. the chromium to form a carbide.
The choice depends on the This renders the chromium in
composition of the steel and the the steel less effective.
operating requirements. The amount of carbon dioxide
which can be tolerated
General guidelines: depends on the chromium
● Penetration increases with the content.
addition of helium. Penetration
also increases with higher
carbon dioxide contents.
● Choose Ferromaxx™ 7 if work
is wholly thin material. Ferro-
maxx™ 15 gives better results
on a wider range of material
thicknesses with the benefit of
reduced ozone emissions. It Ferromaxx™ Plus
can be used successfully on
thin materials but penetration in
butt joints may be more difficult
to control.
● Ferromaxx™ Plus is the multi-
purpose high performance
shielding gas which can be
used in place of Ferromaxx™ 7
or Ferromaxx™ 15 and which CO2
also gives exceptionally low
ozone emissions.
● Carbon dioxide can be useful ❛ Reduce spatter and improve
for fillet welds in thickplate.
profile with Ferromaxx™and
● Spatter increases with increase minimise post weld grinding. ❜
in carbon dioxide content.

26
 THE RIGHT GAS

Gases for MIG/MAG welding

Ferromaxx™ Ferromaxx™ Ferromaxx™ Carbon

Type of steel
7 15 Plus dioxide

Carbon,
Carbon-manganese 4 4 4 4
Structural

Carbon-molybdenum 4 4 4 4
1.5%Cr 0.5%Mo 4 4 4 8
2.5%Cr 1%Mo 4 4 4 8
5%Cr 1%Mo See Note 8 See Note 8

Notes: In many applications Argon-2% oxygen is preferred for the welding of steels containing 5% Cr.
Always seek technical advice before recommending a gas for these steels.

Benefits of Ferromaxx™

less spatter
smooth surface
stable arc gives
uniform width
better profile

27
Air Products Welder’s Handbook

Inomaxx™ Plus = 63% argon, 35% helium, 2% CO2

Gases for MIG/MAG welding Inomaxx™ 2 = 98% argon, 2% CO2
Alumaxx™ Plus = argon 70%, helium 30%

Stainless steel
Inomaxx™ Plus Recommended for all material thickness’ on dip, spray and pulse
transfer. Stable arc conditions offer all-positional capability. Solid
and metal cored wires. Excellent weld bead profiles and appearance
with very little oxidation. Suitable for manual, automated and robotic
welding.

Inomaxx™ 2 Recomended for materials up to 10mm thick on dip, spray and pulse
transfer. Offers all-positional capability with solid wires.

argon + 1% to 3% Suitable only for spray transfer.

oxygen

Aluminium and alloys

Alumaxx™ Plus Recommended for all material thickness’ on spray and pulse transfer.
Higher arc temperatures promotes better penetration and increased
welding speeds. Produces less porosity. Suitable for manual,
automated and robotic welding.

argon + 75% helium Suitable for very thick sections.

argon Stable and controllable arc.

Suitable for pure alluminium and all alloys.

Copper and alloys

Alumaxx™ Plus Recommended for all material thickness’ in spray and pulse transfer.
Improved welding speeds and penetration profiles. Suitable for
manual, automated and robotic welding.

argon + 15% to Spray transfer only.

25% nitrogen

argon Use for sheet and metals up to 9mm thick.

Nickel and alloys

Alumaxx™ Plus Recommended for all material thickness’ in spray and pulse transfer.
Enhanced weld bead profiles and increased penetration. Suitable
for manual, automated and robotic welding.

argon Use for sheet and plate up to 9mm thick.

Suitable for pulse techniques.

28
 THE RIGHT GAS

Gases for TIG welding

Shielding gas Metal

Pure argon All commercially fabricated metals.

Alumaxx™ Plus Aluminium and alloys - all thickness’ Copper and alloys - all
thickness’ Nickel and alloys - all thickness’ Stainless steels - all
thickness’ Suitable for manual, automated, orbital and robotic
welding.

Helium 75% Thick section aluminium and alloys Thick section copper
argon 25% and alloys.

Inomaxx™ TIG Austenitic stainless steel - all thickness’ Nickel and alloys - all
thickness’ Suitable for manual, automated, orbital and robotic
welding.

argon + 1% to 3% Austenitic stainless steels Nickel and alloys.

hydrogen

argon + 5% Austenitic stainless steels - automated, orbital welding

hydrogen Nickel and alloys - automated, orbital welding.

Alumaxx™ Plus = argon 70%, helium 30%

Inomaxx™ TIG = argon 68%, helium 30%, hydrogen 2%

Benefits of Alumaxx™ Plus gases Benefits of Inomaxx™ TIG gases

● enhanced heat transfer ● increased welding speed
● suitable for use on metals with ● improved penetration
a high thermal conductivity ● less surface oxidation
especially in thick sections
● lower gas consumption and
● deeper penetration overall costs
● faster welding speeds ● less post-weld cleaning
● lower ozone emissions ● lower ozone emissions

29
Air Products Welder’s Handbook

Useful data for MIG/MAG welding

Optimum current ranges for steel wire

Electrode diameter (mm) Current range (A)

0.6 40–100
0.8 40–150
1.0 100–280
1.2 120–350
1.6 150–450

Length of electrode wire per kilogram

Electrode Approximate length per kilogram (metre)

diam mm Carbon steel Stainless steel Aluminium
0.8 125 122 364
1.0 95 93 276
1.2 55 54 160
1.6 30 29 87

Melting rate of carbon steel filler wires m/min

18
700 17
16
600 15
14
Wire feed speed in/min

13
500
12
m

m 11
m

m
400 1.0 10
8
0.

9
mm 8
300 1.2
7
m 6
200 1.6 m 5
4
3
100 2
1
50 100 150 200 250 300 350 400 450
Welding current A

30
 WELDING DATA

Typical conditions for MIG/MAG welding sheet

Sheet thickness Joint Electrode Current Voltage Gas (1)

mm swg in gap mm dia mm A V

Carbon steel

0.9 20 1
/32 0.8 0.8 55 - 65 16 - 17 Ferromaxx™ Plus
1.2 18 3
/64 0.8 0.8 80 - 100 17 - 19 Ferromaxx™ Plus

1.6 16 1
/16 0.8 0.8 90 - 110 17 - 19 Ferromaxx™ Plus
2.0 14 5
/64 0.8 0.8 110 - 130 18 - 20 Ferromaxx™ Plus

}
3.2 10 1
/8 0.8 1.0 180 - 200 20 - 23 Ferromaxx™ Plus
4.0 8 5
/32 1.2 1.0 180 - 200 20 - 23 Ferromaxx™ Plus

6.0(2) 4 1
/4 1.6 1.0 180 - 200 20 - 23 Ferromaxx™ Plus

Stainless steel
1.6 16 1
/16 1.0 0.8 70 - 90 19 - 20 Inomaxx™ Plus

2.0 14 5
/64 1.0 1.0 75 - 95 19 - 20 Inomaxx™ Plus
3.2 10 1
/8 1.0 1.0 90 - 130 18 - 21 Inomaxx™ Plus

6.0(2) 4 1
/4 1.6 1.2 180 - 240 22 - 26 Inomaxx™ Plus

Aluminium and alloys

1.6(3) 16 1
/18 1.0 1.0 70 - 100 17 - 18 Alumaxx™ Plus
2.0(3) 14 5
/64 1.0 1.0 70 - 100 17 - 18 Alumaxx™ Plus

3.2 10 1
/8 1.0 1.2 100 - 130 19 - 20 Alumaxx™ Plus
6.0(2) 4 1
/4 1.6 1.2 150 - 200 26 - 29 Alumaxx™ Plus

Notes: (1) Gas flow rate: 14 to 16l/min (higher flow rates may be required with gases containing helium)
(2) Welded from both sides
(3) Pulsed transfer

31
Air Products Welder’s Handbook

Typical conditions for MIG/MAG welding plate

Butt joints in flat position Fillet welds in flat position
Run Wire Current Voltage Leg Number
length Wire Current Voltage of
dia mm A V mm dia mm A V runs

Carbon steel – Ferromaxx™ Plus 6 1.2 300–320 31–33 1

or Ferromaxx™15
10 1.2 290–310 30–32 2
Root 1.0 90–100 17–19
Second 1.2 260–270 29–31 12 1.2 290–310 30–32 4
Filling 1.2 280–300 31–33
Stainless steel – Inomaxx™ Plus
Root 0.8 80–85 19–21
Second 1.6 220–230 22–24
Filling 1.6 265–275 25–27
4
Aluminium & alloys – Alumaxx™ Plus
2 3
Root 1.0 85–95 20–22 1
Second 1.6 210–220 24–26
Filing 1.6 230–240 24–26
Butt and fillet welds in vertical position

use a
triangular
▼

weave
mm mm A V
ensure 6 1.0 80–95 17–18 1
fusion
in the 10 1.0 70–180 19–20 1
root
12 (1) 1.0 80–95 17–18 2
12 (2) 1.0 70–180 19–20 2
(1) Root run deposited vertical-down (2) Filling run deposited with weave moving up the joint.

32
 FLUX CORED WIRES DATA

Useful data for flux cored wires

Optimum current ranges for steel electrodes
Wire Current Wire Current
dia mm range A dia mm range A
1.2 100 - 280 2.4 300 - 525
1.6 140 - 350 3.2 400 - 650
2.0 200 - 425
Current ranges vary according to cored wire type.

Typical welding conditions for flux cored wires

Steel plate - Ferromaxx™ Plus shielding gases at 20 l/min
Butt welds - flat position
Run Wire Current Voltage
dia mm A V
Root 1.2 140 - 180 18
Second 2.4 350 - 430 25
Filling 2.4 350 - 430 25
All welds - vertical position all runs
Run Wire Current Voltage
dia mm A V
Root 1.2 130 - 165 18
Second 1.2 150 - 170 18
Filling (weaved) 1.2 170 - 200 20
Fillet welds - flat and horizontal - vertical positions; single pass
Leg length Wire Current Voltage
mm dia mm A V
4.5 2.0 325 - 375 25
6.0 2.4 400 - 450 30
10.0 2.4 450 - 525 32
Note: 10mm leg length fillet weld — flat position only

33
Air Products Welder’s Handbook

Typical conditions for TIG welding

Butt Joints
Recommended joint preparation
o
65 - 75 o

removable backing no sheet

gap=half root gap
thickness 1mm 1.6mm

up to 3.2mm up to 3.2mm 4.8mm and thicker

Metal Electrode Filler rod Welding Shielding

thickness diameter diameter current gas flow
mm mm mm A l/min
Aluminium — alternating current — zirconiated electrode
1.6 1.6 60 – 80 6
3.2 3.2 2.4 125 – 145 7
4.8 4.0 3.2 180 – 220 10
6.0 4.8 4.8 235 – 275 12
Stainless steel — direct current — thoriated electrode
1.6 1.6 1.6 60 – 70 5
3.2 2.4 2.4 70 – 95 6
4.8 2.4 3.2 100 – 120 7
6.0 3.2 4.0 135 – 160 8
Carbon steel — direct current — thoriated electrode
1.6 1.6 1.6 60 – 70 5
3.2 1.6 or 2.4 2.4 75 – 95 6
4.8 2.4 3.2 110 – 130 7
6.0 3.2 4.8 155 – 175 8

34
 TIG WELDING DATA

Typical conditions for TIG welding

T Joints - fillet welded

ensure surface along

joint line is free of
oxides and grease up to
up to 3.2
3.2mm - no gap
mm - no gap
4.8mm
over 4.8 - 0.8mm
m - 0.8 mm gap gap

Metal Electrode Filler rod Welding Shielding

thickness diameter diameter current gas flow
mm mm mm A l/min
Aluminium — alternating current — zirconiated electrode
1.6 2.4 1.6 60 – 80 5
3.2 3.2 2.4 130 – 160 6
4.8 3.2 or 4.0 3.2 195 – 230 7
6.0 4.0 or 4.8 4.8 260 – 295 10
Stainless steel — direct current — thoriated electrode
1.6 1.6 1.6 50 – 70 5
3.2 2.4 2.4 85 – 105 5
4.8 2.4 3.2 120 – 145 6
6.0 3.2 4.0 165 – 180 7
Carbon steel — direct current — thoriated electrode
1.6 1.6 1.6 50 – 70 5
3.2 1.6 or 2.4 2.4 90 – 120 5
4.8 2.4 3.2 135 – 175 6
6.0 3.2 4.8 170 – 200 7

35
Air Products Welder’s Handbook

Typical conditions for TIG welding

Corner joints

no gap 1mm gap

up to 3.2mm thickness 4.8mm and thicker

Metal Electrode Filler rod Welding Shielding

thickness diameter diameter current gas flow
mm mm mm A l/min
Aluminium — alternating current — zirconiated electrode
1.6 2.4 1.6 50 – 70 6
3.2 2.4 or 3.2 2.4 100 – 120 7
4.8 3.2 or 4.0 3.2 175 – 210 10
6.0 4.0 or 4.8 4.8 220 – 260 12
Stainless steel — direct current — thoriated electrode
1.6 1.6 1.6 40 – 55 6
3.2 2.4 2.4 50 – 75 7
4.8 2.4 3.2 90 – 110 8
6.0 3.2 4.0 125 – 150 10
Carbon steel — direct current — thoriated electrode
1.6 1.6 1.6 40 – 60 6
3.2 1.6 or 2.4 2.4 70 – 90 7
4.8 2.4 3.2 110 – 130 8
6.0 3.2 4.8 155 – 175 10

36
 OXYGEN CUTTING

Oxygen-fuel gas cutting

Principles
Oxygen-fuel gas cutting is widely
used to cut:
● straight lines and shapes in
plates
● pipe end in preparation for
welding
● scrap metal

It can produce a variety of edge

profiles on plates, pipes and sections
Metal Cutting response
nozzle

Mild and low

Very good
preheat carbon steels
flame cutting oxygen jet
Must use flux in
Stainless steel oxygen jet.
Poor quality cut

cut face molten slag and

metal ejected from cut Aluminium,
Unsuitable
copper etc

The cutting action depends on a

chemical reaction between oxygen
and hot iron or steel.

A preheat-flame is used to raise the

surface of the metal to the tempera-
ture at which the reaction takes
place. ❛ Air Products’ oxygen has the right
purity for fast cutting. Do not use
The heat from the reaction melts the damaged nozzles if you want the
metal which is blown from the cut by
best results. ❜
Metal
the oxygen jet.Metal

37
Air Products Welder’s Handbook

Equipment For safety, hoses must be fitted with

hose protectors at the torch.
The essential equipment for cutting
comprises: nut to connect to torch
● cutting and torch hoses
● oxygen regulator (14 bar max
output)
● fuel gas regulator (2 bar max flow
output)

Oxygen and fuel gas for the preheat

flame are mixed in the nozzle. disk valve closed
when gas flow
reverses
The type of nozzle is matched to the
fuel gas.

Witt Super 78 and Air Products

Flashback arrestors.
head
assembly cutting oxygen
pre-heat oxygen
pre-heat fuel

seatings

nut

nozzle

38
 OXYGEN CUTTING

Preheat flame

The preheat flame: Fuel gas can be:

● heats the metal to start the Apachi+™ — propylene based gas,
cutting action exclusive to Air Products PLC.
● heats the surface along the line
of the cut to keep the cutting Acetylene — colourless unsaturated
action going hydrocarbon.

● disperses residual paint and Propane — liquified petroleum based

oxide on the surface gas.

Choice of fuel gas depends on:

Factor for choice Apachi+ Acetylene Propane

Time to start cut ●● ●●● ●
Cutting speed ●●● ●●● ●●
Fuel gas cost ●● ● ●●●
Heating oxygen cost ●● ●●● ●
Ease of handling ●●● ● ●●●

● ● ● = best choice ● = worst choice

39
Air Products Welder’s Handbook

kerf width
Quality of cut
sharp edge
The aim is to produce a cut with:
smooth face
● a uniform gap (kerf)
● clearly defined edges
● smooth faces
● no adhering slag no slag bridge

The quality of a cut surface depends on a number of variables

Variable Condition Effect

Nozzle-to-plate too low top edge rounded

distance too high undercutting

Cutting oxygen too low cutting stops

pressure too high irregular face variable width
too low excessive melting; slag adheres to face
Cutting speed
too high undercut; slag bridges bottom
too small cutting stops
Preheat flame
too big top edge very rounded

edge rounded

undercut slag adhering to face slag adhering to bottom edge

40
 OXYGEN CUTTING

Operating techniques

Manual cutting is used for short cuts

and the removal of defective parts.

It is difficult to achieve a uniform cut

with manual techniques. Variations in
travel speed and nozzle-to-plate
distance give irregular cut faces.

Improved results can be obtained by

the use of guides for straight lines . . .

fixed template

. . . and radius bars for circles.

constant
distance

41
Air Products Welder’s Handbook

Operating techniques

Mechanised cutting produces a

superior finish to manual operation.

A variety of mechanised traversing

systems are available or the torch
can be moved along a straight line or
by hand to produce a complex shape.

leading trailing
nozzle nozzle

Mechanised systems can be used to

prepare the edges of plate prior to
welding.

More than one cut can be made at

the same time.

42
 OXYGEN CUTTING

Typical operating conditions

Plate thickness mm 6 9 12 18 25 35 50
Nozzle size - in 1/32 1/32 3/64 3/64 1/16 1/16 1/16
Cutting speed
in/min 24 22 21 15 13 12 11.5
mm/sec 10.2 9.3 8.9 6.3 5.5 5.1 4.9
Cutting oxygen
pressure — bar 1.8 1.8 2.1 2.1 2.8 3.2 3.2
pressure — psi 25 25 30 30 40 45 45
flow rate l/hr 650 950 1150 1600 2000 2500 3300
Preheat gas
pressure — bar .14 .21 .21 .21 .30 .30 .30
pressure — psi 2 3 3 3 4 4 4
flow rate l/hr
Apachi+ 250 260 295 295 340 400 400
oxygen 900 950 1025 1025 1150 1350 1350
Acetylene 310 320 340 340 400 430 430
oxygen 340 355 375 375 440 475 475
Propane 255 265 300 300 350 400 400
oxygen 1080 1125 1275 1275 1475 1720 1720

Note: These conditions provide a starting point. Precise settings depend on the type of nozzle,
nozzle-to-plate distance and the condition of the plate surface.

43
Air Products Welder’s Handbook

Plasma arc cutting The arc operates in an inert inner

shield, whilst an outer shield provides
protection for the cut surface.
Accurate cuts can be made in stain-
less steel and non-ferrous metals such
Argon, helium, nitrogen and mixtures
as aluminium by plasma arc cutting.
of these gases are used for both the
inner and outer shields.
The cuts are made by a high
temperature, high velocity gas jet
Plasma arc cutting is characterised by
generated by constricting an arc
fast cutting speeds and is mainly used
between a tungsten electrode and the
in mechanised systems.
component.
The cutting is accompanied by a high
The heat from the arc melts the metal
noise level which can be reduced by
and the gas jet removes the molten
operating the torch under water.
metal from the cut.

ceramic shroud

tungsten electrode

plasma gas

shielding gas

plasma (arc) stream

44
 PLASMA ARC CUTTING

Hytec 35 Benefits of Hytec 35

Hytec 35 is a gas mixture which has

● Increased cutting speed
been specially formulated for plasma
arc cutting. It contains 65% argon and ● Reduced oxidation
35% hydrogen. ● Narrow kerf — less metal
wastage
Hytec 35 is used as the plasma gas.
The shielding gas can be nitrogen or ● Clean cut surface
argon. ● Handles thicker section
material

Hytec 35 - plasma cutting parameter guide

Plate Speed Orifice size Power Flow rate

thickness mm mm/min mm kW l/min
6 7607 3 60 82.6
12 2536 3 70 82.6
25 1268 4 80 94.4
Aluminium
50 507 4 80 94.4
75 380 5 90 94.4
100 304 5 90 94.4
12 2536 3 60 70.8
25 1268 4 80 80.2
Stainless
Steel 50 507 4 100 94.4
75 406 5 100 94.4
100 203 5 100 94.4

For specific parameters and gas flow rates consult your equipment manual.

45
Air Products Welder’s Handbook

Golden rules for safe handling of welding and cutting gases

Safety always — accidents never

Always understand the properties Never attempt to repair or modify
and hazards associated with each cylinder valves or safety relief
gas before using it. devices.

Never remove or obscure official

Always wear suitable eye and face labelling on a gas cylinder and
protection when dealing with gas. always check the identity of a gas
before using it.
Always store cylinders in the
Never smoke when dealing with gas.
vertical position, and ensure that
they are properly secured.
Never use direct heat on a cylinder.
Keep cylinders cool.
Always protect your hands! Wear
stout gloves when handling gas Never allow oil or grease on
cylinders. cylinders and valves and always
close the valve when not in use.

Always use a proper trolley for Never lift a cylinder by its cap,
moving cylinders, even for a short guard or valve. Always replace caps
distance. and guards.

46
 Air Products Welding Specialists provide technical advice
to companies and individuals in the welding industry
throughout the UK and Ireland.

Why not let our team of experts assist you

with your welding queries.

Our trained staff are on hand to provide the answers

you need, ensuring you get the best weld every time.

Air Products
DIRECT
0800 389 02 02

Air Products PLC

1 Millennium Gate, Westmere Drive, Crewe, Cheshire, CW1 6AP

Air Products Ireland Ltd

Unit 950, Western Industrial Estate, Killeen Road, Dublin 12, Republic of Ireland

www.airproducts.com/maxx