Shielding gas

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Shielding gases are inert or semi-inert gases that are commonly used in several

welding processes, most notably gas metal arc welding and gas tungsten arc
welding (GMAW and GTAW, more popularly known as MIG (Metal Inert Gas) and
TIG (Tungsten Inert Gas), respectively). Their purpose is to protect the weld area
from oxygen, and water vapour. Depending on the materials being welded, these
atmospheric gases can reduce the quality of the weld or make the welding more
difficult. Other arc welding processes use alternative methods of protecting the
weld from the atmosphere as well – shielded metal arc welding, for example, uses
an electrode covered in a flux that produces carbon dioxide when consumed, a
semi-inert gas that is an acceptable shielding gas for welding steel.
Improper choice of a welding gas can lead to a porous and weak weld, or to
excessive spatter; the latter, while not affecting the weld itself, causes loss of
productivity due to the labor needed to remove the scattered drops.
If used carelessly, shielding gasses can displace oxygen, causing hypoxia and
potentially death.[medical citation needed][1]

Contents

 1Common shielding gases

 2Properties
o 2.1Common mixes
 3Applications
 4See also
 5External links
 6References

Common shielding gases[edit]

Shielding gases fall into two categories—inert or semi-inert. Only two of the noble
gases, helium and argon, are cost effective enough to be used in welding. These
inert gases are used in gas tungsten arc welding, and also in gas metal arc welding
for the welding of non-ferrous metals. Semi-inert shielding gases, or active shield
gases, include carbon dioxide, oxygen, nitrogen, and hydrogen. These active
gases are used with GMAW on ferrous metals. Most of these gases, in large
quantities, would damage the weld, but when used in small, controlled quantities,
can improve weld characteristics.

Properties[edit]
The important properties of shielding gases are their thermal conductivity and heat
transfer properties, their density relative to air, and the ease with which they
undergo ionization. Gases heavier than air (e.g. argon) blanket the weld and
require lower flow rates than gases lighter than air (e.g. helium). Heat transfer is
important for heating the weld around the arc. Ionizability influences how easy the
arc starts, and how high voltage is required. Shielding gases can be used pure, or
as a blend of two or three gases.[2][3] In laser welding, the shielding gas has an
additional role, preventing formation of a cloud of plasma above the weld,
absorbing significant fraction of the laser energy. This is important for CO 2 lasers;
Nd:YAG lasers show lower tendency to form such plasma. Helium plays this role
best due to its high ionization potential; the gas can absorb high amount of energy
before becoming ionized.
Argon is the most common shielding gas, widely used as the base for the more
specialized gas mixes.[4]
Carbon dioxide is the least expensive shielding gas, providing deep penetration,
however it negatively affects the stability of the arc and enhances the molten
metal's tendency to create droplets (spatter). [5] Carbon dioxide in concentration of
1-2% is commonly used in the mix with argon to reduce the surface tension of the
molten metal. Another common blend is 25% carbon dioxide and 75% argon for
GMAW.[6]
Helium is lighter than air; larger flow rates are required. It is an inert gas, not
reacting with the molten metals. Its thermal conductivity is high. It is not easy to
ionize, requiring higher voltage to start the arc. Due to higher ionization potential it
produces hotter arc at higher voltage, provides wide deep bead; this is an
advantage for aluminium, magnesium, and copper alloys. Other gases are often
added. Blends of helium with addition of 5–10% of argon and 2–5% of carbon
dioxide ("tri-mix") can be used for welding of stainless steel. Used also for
aluminium and other non-ferrous metals, especially for thicker welds. In
comparison with argon, helium provides more energy-rich but less stable arc.
Helium and carbon dioxide were the first shielding gases used, since the beginning
of World War 2. Helium is used as a shield gas in laser welding for carbon dioxide
lasers.[7] Helium is more expensive than argon and requires higher flow rates, so
despite its advantages it may not be a cost-effective choice for higher-volume
production.[8] Pure helium is not used for steel, as it causes an erratic arc and
encourages spatter.
Oxygen is used in small amounts as an addition to other gases; typically as 2–5%
addition to argon. It enhances arc stability and reduces the surface tension of the
molten metal, increasing wetting of the solid metal. It is used for spray transfer
welding of mild carbon steels, low alloy and stainless steels. Its presence increases
the amount of slag. Argon-oxygen (Ar-O2) blends are often being replaced with
argon-carbon dioxide ones. Argon-carbon dioxide-oxygen blends are also used.
Oxygen causes oxidation of the weld, so it is not suitable for welding aluminium,
magnesium, copper, and some exotic metals. Increased oxygen makes the
shielding gas oxidize the electrode, which can lead to porosity in the deposit if the
electrode does not contain sufficient deoxidizers. Excessive oxygen, especially
when used in application for which it is not prescribed, can lead to brittleness in the
heat affected zone. Argon-oxygen blends with 1–2% oxygen are used for austenitic
stainless steel where argon-CO2 can not be used due to required low content of
carbon in the weld; the weld has a tough oxide coating and may require cleaning.
Hydrogen is used for welding of nickel and some stainless steels, especially
thicker pieces. It improves the molten metal fluidity, and enhances cleanness of the
surface. It is added to argon in amounts typically under 10%. It can be added to
argon-carbon dioxide blends to counteract the oxidizing effects of carbon dioxide.
Its addition narrows the arc and increases the arc temperature, leading to better
weld penetration. In higher concentrations (up to 25% hydrogen), it may be used
for welding conductive materials such as copper. However, it should not be used
on steel, aluminum or magnesium because it can cause porosity and hydrogen
embrittlement; its application is usually limited only to some stainless steels.
Nitric oxide addition serves to reduce production of ozone. It can also stabilize the
arc when welding aluminium and high-alloyed stainless steel.
Other gases can be used for special applications, pure or as blend additives;
e.g. sulfur hexafluoride or dichlorodifluoromethane.[9]
Sulfur hexafluoride can be added to shield gas for aluminium welding to bind
hydrogen in the weld area to reduce weld porosity. [10]
Dichlorodifluoromethane with argon can be used for protective atmosphere for
melting of aluminium-lithium alloys.[11] It reduces the content of hydrogen in the
aluminium weld, preventing the associated porosity.
Common mixes[edit]

 Argon-carbon dioxide
o C-50 (50% argon/50% CO2) is used for short arc welding of pipes,
o C-40 (60% argon/40% CO2) is used for some flux-cored arc
welding cases. Better weld penetration than C-25.
o C-25 (75% argon/25% CO2) is commonly used by hobbyists and in
small-scale production. Limited to short circuit and globular transfer
welding. Common for short-circuit gas metal arc welding of low carbon
steel.
o C-20 (80% argon/20% CO2) is used for short-circuiting and spray
transfer of carbon steel.
o C-15 (85% argon/15% CO2) is common in production environment for
carbon and low alloy steels. Has lower spatter and good weld penetration,
suitable for thicker plates and steel significantly covered with mill scale.
Suitable for short circuit, globular, pulse and spray transfer welding.
 Maximum productivity for thin metals in short-circuiting mode; has lower
tendency to burn through than higher-CO2 mixes and has suitably high
deposition rates.
o C-10 (90% argon/10% CO2) is common in production environment.
Has low spatter and good weld penetration, though lower than C-15;
suitable for many steels. Same applications as 85/15 mix. Sufficient for
ferritic stainless steels.
o C-5 (95% argon/5% CO2) is used for pulse spray transfer and short-
circuiting of low alloy steel. Has better tolerance for mill scale and better
puddle control than argon-oxygen, though less than C-10. Less heat than
C-10.[12] Sufficient for ferritic stainless steels. Similar performance to argon
with 1% oxygen.
 Argon-oxygen
o O-5 (95% argon/5% oxygen) is the most common gas for general
carbon steel welding. Higher oxygen content allows higher speed of
welding. More than 5% oxygen makes the shielding gas oxidize the
electrode, which can lead to porosity in the deposit if the electrode does not
contain sufficient deoxidizers.
o O-2 (98% argon/2% oxygen) is used for spray arc on stainless steel,
carbon steels, and low alloy steels. Better wetting than O-1. Weld is darker
and more oxidized than with O-1. The addition of 2% oxygen encourages
spray transfer, which is critical for spray-arc and pulsed spray-arc GMAW.
o O-1 (99% argon/1% oxygen) is used for stainless steels. Oxygen
stabilizes the arc.
 Argon-helium
o A-25 (25% argon/75% helium) is used for nonferrous base when
higher heat input and good weld appearance are needed.
o A-50 (50% argon/50% helium) is used for nonferrous metals thinner
than 0.75 inch for high-speed mechanized welding.
o A-75 (75% argon/25% helium) is used for mechanized welding of
thick aluminium. Reduces weld porosity in copper.[13]
 Argon-hydrogen
o H-2 (98% argon/2% hydrogen)
o H-5 (95% argon/5% hydrogen)
o H-10 (80% argon/20% hydrogen)
o H-35 (65% argon/35% hydrogen)[14]
 Others
o Argon with 25–35% helium and 1–2% CO2 provides high productivity
and good welds on austenitic stainless steels. Can be used for joining
stainless steel to carbon steel.
o Argon-CO2 with 1–2% hydrogen provides a reducing atmosphere that
lowers amount of oxide on the weld surface, improves wetting and
penetration. Good for austenitic stainless steels.
 o Argon with 2–5% nitrogen and 2–5% CO2 in short-circuiting yields
good weld shape and color and increases welding speed. For spray and
pulsed spray transfer it is nearly equivalent to other mixes. When joining
stainless to carbon steels in presence of nitrogen, care has to be taken to
ensure the proper weld microstructure. Nitrogen increases arc stability and
penetration and reduces distortion of the welded part. In duplex stainless
steels assists in maintaining proper nitrogen content.
o 85–95% helium with 5–10% argon and 2–5% CO2 is an industry
standard for short-circuit welding of carbon steel.
o Argon – carbon dioxide – oxygen
o Argon–helium–hydrogen
o Argon – helium – hydrogen – carbon dioxide

Applications[edit]
The applications of shielding gases are limited primarily by the cost of the gas, the
cost of the equipment, and by the location of the welding. Some shielding gases,
like argon, are expensive, limiting its use. The equipment used for the delivery of
the gas is also an added cost, and as a result, processes like shielded metal arc
welding, which require less expensive equipment, might be preferred in certain
situations. Finally, because atmospheric movements can cause the dispersion of
the shielding gas around the weld, welding processes that require shielding gases
are often only done indoors, where the environment is stable and atmospheric
gases can be effectively prevented from entering the weld area.
The desirable rate of gas flow depends primarily on weld geometry, speed, current,
the type of gas, and the metal transfer mode being utilized. Welding flat surfaces
requires higher flow than welding grooved materials, since the gas is dispersed
more quickly. Faster welding speeds, in general, mean that more gas needs to be
supplied to provide adequate coverage. Additionally, higher current requires
greater flow, and generally, more helium is required to provide adequate coverage
than argon. Perhaps most importantly, the four primary variations of GMAW have
differing shielding gas flow requirements—for the small weld pools of the short
circuiting and pulsed spray modes, about 10 L/min (20 ft3/h) is generally suitable,
while for globular transfer, around 15 L/min (30 ft3/h) is preferred. The spray
transfer variation normally requires more because of its higher heat input and thus
larger weld pool; along the lines of 20–25 L/min (40–50 ft3/h).[15]

See also[edit]
 Forming gas

External links[edit]
 Shielding Gas Handbook
References[edit]
1. ^ Jawaid, Asra.  "Dealing With Welding Fumes  : Resources  : American Welding
Society". www.aws.org.
2. ^ Lyttle, Kevin. (2005-01-11) Simplifying shielding gas selection. TheFabricator.
Retrieved on 2010-02-08.
3. ^ The Evolution of Shielding Gas. Aws.org. Retrieved on 2010-02-08.
4. ^ Advanced welding supply gas type guide
5. ^ What You Should Know About Shielding Gas
6. ^ Choosing a Shielding Gas for Flux-Cored Welding
7. ^ Dawes, Christopher (1992), Laser welding: a practical guide, Woodhead Publishing,
p.  89, ISBN 978-1-85573-034-2.
8. ^ Bernard – Great Welds Need The Right Gas: How Shielding Gas Can Make Or Break
Your Weld Archived 2010-09-18 at the Wayback Machine. Bernardwelds.com. Retrieved on
2010-02-08.
9. ^ Shielding gas for laser welding – Patent 3939323. Freepatentsonline.com. Retrieved
on 2010-02-08.
10. ^ Method of welding material with reduced porosity – Patent Application 20070045238.
Freepatentsonline.com (2005-08-29). Retrieved on 2010-02-08.
11. ^ Blanketing atmosphere for molten aluminum-lithium or pure lithium – Patent
EP0268841. Freepatentsonline.com. Retrieved on 2010-02-08.
12. ^ Argon-Carbon Dioxide Mixtures – Praxair's StarGold and Mig Mix Gold
Blends Archived 2010-01-13 at the Wayback Machine. Praxair.com. Retrieved on 2010-02-08.
13. ^ Argon-helium mixtures for coated steel welding
14. ^ Shielding gas cross-reference chart
15. ^ Cary, Howard B.; Helzer, Scott C. (2005),  Modern Welding
Technology (6th  ed.), Prentice Hall, pp. 123–125, ISBN 0-13-113029-3.

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