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SHIELDING GASES IN CONVENTIONAL WELDING APPLICATIONS: A GLIMPSE

OF WELD INTEGRITY IN THE MANUFACTURING SECTOR

Conference Paper · March 2024

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INTERNATIONAL SCIENCE AND ART RESEARCH CENTER

SHIELDING GASES IN CONVENTIONAL WELDING APPLICATIONS: A GLIMPSE

OF WELD INTEGRITY IN THE MANUFACTURING SECTOR

Aniekan Essienubong IKPE

Department of Mechanical Engineering Technology, Akwa Ibom State Polytechnic, Ikot Osurua, PMB
1200
ORCID ID: 0000-0001-9069-9676
Etuk Ekom MIKE
Department of Production Engineering, University of Benin, Benin City, PMB 1154
ORCID ID: 0000-0002-1866-9349
Emem Okon IKPE
Department of Science Technology, Akwa Ibom State Polytechnic, Ikot Osurua, PMB 1200
ORCID ID: 0000-0001-8093-9904

ABSTRACT
This study aimed to provide a comprehensive overview of the role of shielding gases in ensuring
weld integrity in the manufacturing sector. It explored the various types of shielding gases
commonly used in welding processes and their impact on weld quality, focusing on different
welding processes, including gas metal arc welding (GMAW), gas tungsten arc welding
(GTAW), and flux-cored arc welding (FCAW). The results showed that the choice of shielding
gas significantly affects the weld characteristics, such as bead appearance, penetration depth, and
porosity. Arguably, argon was observed as the most commonly used shielding gas in welding,
providing excellent protection against atmospheric contamination and produces high-quality
welds, but may not be suitable for all applications. For instance, when welding reactive metals
like titanium, helium is often preferred due to its higher thermal conductivity and lower
ionization potential. Carbon dioxide-based shielding gases, although more prone to spatter,
provide deeper penetration and higher welding speeds. However, they may result in increased
porosity and reduced weld aesthetics. The influence of gas composition on weld properties was
another important finding. The findings revealed that the addition of small amounts of oxygen to
argon can improve arc stability and reduce spatter in GMAW. Similarly, the addition of hydrogen
to argon can enhance the weld penetration in GTAW. Helium, when used in combination with
argon, can improve weld penetration and heat input, making it suitable for welding thicker
materials. The study indicated that argon is relatively expensive compared to other gases, such as
carbon dioxide or mixtures of argon and carbon dioxide.

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Therefore, manufacturers need to strike a balance between weld quality and cost-effectiveness
when selecting the appropriate shielding gas, while tailoring the shielding gas composition to a
specific welding process to achieve desired weld characteristics.
Keywords: shielding gases, weld integrity, manufacturing sector, weld quality, cost-
effectiveness.
1. Introduction
Shielding gases are an essential component in the welding process, as they play a crucial role in
ensuring weld integrity. These gases are used to protect the molten weld pool from atmospheric
contamination, which can lead to defects such as porosity, cracking, and lack of fusion. In this
study, the definition and principles of shielding gases for weld integrity is discussed. Shielding
gases are inert or semi-inert gases that are used to protect the weld pool from atmospheric
contamination during the welding process (Madavi et al., 2022). These gases create a barrier
between the molten metal and the surrounding air, preventing oxidation and other harmful
reactions that can compromise the quality of the weld. The most commonly used shielding gases
in welding are argon, helium, and carbon dioxide, each of which has its own unique properties
and applications (Kang et al, 2009). The principles of shielding gases for weld integrity are based
on the need to create a stable and protective environment around the weld pool. This is achieved
by selecting the appropriate gas for the specific welding process and material being used, as well
as controlling the flow rate and distribution of the gas to ensure complete coverage of the weld
area (Ikpe et al., 2023). The choice of shielding gas can have a significant impact on the quality
of the weld, as different gases have different effects on the weld pool and the resulting weld bead.
Argon is often used as a shielding gas for TIG (tungsten inert gas) welding, as it provides
excellent coverage and stability for the weld pool. Helium is commonly used in combination with
argon for welding materials such as aluminium, as it helps to increase heat input and penetration.
Carbon dioxide is frequently used in MIG (metal inert gas) welding, as it provides good
penetration and helps to stabilize the arc (Kleemeyer, 2021). Shielding gases are a critical
component of the welding process, as they play a key role in ensuring weld integrity. By
understanding the principles of shielding gases and selecting the appropriate gas for the specific
welding application, welders can achieve high-quality welds that meet the required standards for
strength and durability (Kikani, 2016). Proper use of shielding gases is essential for achieving
weld integrity and producing high-quality welds. Shielding gases are standardized in accordance

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with standard DIN EN ISO 14175 (AWS A5.32) and are classified into seven main groups
highlighted as follows:
i. I: Inert gases and inert mixed gases.
ii. M1, M2, M3: Oxidizing mixed gases with oxygen and/or carbon dioxide.
iii. C: Very oxidizing gases and very oxidizing mixed gases.
iv. R: Reducing mixed gases.
v. N: Non-reactive gases or non-reactive mixed gases with nitrogen.
vi. O: Oxygen.
vii. Z: Mixed gases that cannot be classified in accordance with the aforementioned criteria.

This study provides a glimpse of weld integrity in the manufacturing sector in relation to
shielding gases in conventional welding applications.
2. History of Weld Shielding Gases
Weld shielding gases have played a crucial role in the development of welding processes over the
years. The use of shielding gases in welding dates back to the early 20th century, when
researchers began to experiment with different gases to protect the weld pool from atmospheric
contamination. This led to the development of various welding processes, such as gas metal arc
welding (GMAW) and gas tungsten arc welding (GTAW), which rely on shielding gases to create
a stable arc and produce high-quality welds (Bera, 2020). One of the earliest forms of shielding
gas used in welding was carbon dioxide (CO2). In the 1920s, researchers discovered that CO2
could be used as a shielding gas in welding processes, leading to the development of the CO2
welding process. This process was widely used during World War II for shipbuilding and other
industrial applications, due to its ability to produce strong and durable welds. In the 1940s,
researchers began to experiment with other gases, such as argon and helium, as shielding gases in
welding processes. Argon was found to be particularly effective in producing high-quality welds,
due to its inert nature and ability to create a stable arc. Helium, on the other hand, was found to
be useful in welding processes that required high heat input, such as aluminium welding
(Zielinska et al., 2008). Over the years, researchers have continued to experiment with different
shielding gases and gas mixtures to improve the quality and efficiency of welding processes.
Today, a wide range of shielding gases are used in welding, including argon, helium, CO2, and
various gas mixtures. These gases are chosen based on the specific requirements of the welding
process, such as the type of material being welded, the welding position, and the desired weld
quality. The history of weld shielding gases is a testament to the importance of innovation and
research in the field of welding (Golbabaei and Khadem, 2015). The development of shielding
gases has revolutionized welding processes, allowing for the production of high-quality welds in

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a wide range of applications. As researchers continue to explore new materials and technologies,
the use of shielding gases in welding is likely to evolve and improve, leading to even greater
advancements in the field.
3. Advancements on Weld Shielding Gases
One of the key components in welding is the use of shielding gases, which are essential for
protecting the weld pool from atmospheric contamination. Over the years, there have been major
advancements in the development of shielding gases, with key milestones that have significantly
improved the welding process (Ley et al., 2015). The key advancements on weld shielding gases
are highlighted as follows:
i. One of the major advancements in shielding gases was the introduction of inert gases such as
argon and helium (Kah and Martikainen, 2013). These gases are non-reactive and provide
excellent protection for the weld pool, resulting in high-quality welds with minimal defects. The
use of inert gases revolutionized the welding industry, allowing for cleaner and more precise
welds to be made.

ii. Another key milestone in the development of shielding gases was the introduction of mixed
gases, such as carbon dioxide and argon blends. These mixed gases offer a combination of the
benefits of both inert and reactive gases, providing improved weld penetration and reduced
spatter (Mariappan et al., 2021). This advancement has allowed for greater flexibility in welding
applications, as different gas blends can be used to achieve specific welding requirements.

iii. In recent years, there has been a growing focus on the development of advanced shielding gas
technologies, such as modified atmospheres and gas mixtures with added elements like oxygen or
nitrogen (Roy et al., 2021). These technologies have been shown to improve weld quality,
increase productivity, and reduce environmental impact. For example, the use of oxygen-enriched
shielding gases has been found to enhance weld pool stability and increase welding speed,
leading to significant cost savings for manufacturers.
The advancements in shielding gases have played a crucial role in improving the efficiency and
quality of welding processes. From the introduction of inert gases to the development of
advanced gas technologies, these milestones have paved the way for innovation in the welding
industry. As technology continues to evolve, we can expect further advancements in shielding
gases that will continue to enhance the welding process and drive progress in various industries.

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4. Characteristics of Weld Shielding Gases

Weld shielding gases play a crucial role in the welding process by protecting the molten weld
pool from atmospheric contamination. The choice of shielding gas can significantly impact the
quality of the weld, as different gases have varying characteristics that can affect the weld bead
appearance, penetration, and overall weld strength. The key characteristics of weld shielding
gases are as follows:
i. One of the key characteristics of weld shielding gases is their ability to prevent oxidation of the
molten weld pool. Oxidation can weaken the weld joint and lead to defects such as porosity and
cracking (Kryukov et al., 2015). Inert gases such as argon and helium are commonly used as
shielding gases because they do not react with the molten metal, providing a stable environment
for the weld to form.

ii. Another important characteristic of shielding gases is their ability to control the heat input
during the welding process. Some gases, such as carbon dioxide, have a higher thermal
conductivity than others, which can result in faster cooling rates and increased distortion in the
weld joint. By selecting the appropriate shielding gas, welders can achieve the desired heat input
and minimize distortion in the final weld (Kutelu et al., 2015).

iii. Additionally, the composition of the shielding gas can impact the weld bead appearance and
penetration. For example, a gas mixture containing a higher percentage of oxygen can improve
weld penetration, while a gas with a higher percentage of helium can produce a wider and flatter
weld bead (Shanping et al., 2005). Welders must consider the specific requirements of the
welding application when selecting the appropriate shielding gas composition.
The characteristics of weld shielding gases play a critical role in determining the quality and
integrity of the weld joint. By understanding the properties of different gases and their effects on
the welding process, welders can make informed decisions to achieve optimal weld quality. It is
essential for welders to carefully consider the specific requirements of each welding application
and select the appropriate shielding gas to ensure successful weld outcomes.

5. Compositions of Weld Shielding Gases

Compositions and mixing ratios for different weld shielding gases are crucial factors in
determining the quality and efficiency of the welding process. Shielding gases are used in
welding to protect the molten weld pool from atmospheric contamination, which can lead to
defects in the weld such as porosity, cracking, and lack of fusion (Tanaka et al., 2008). The

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choice of shielding gas and its composition can significantly impact the final weld quality. The
compositions include the following:
i. Argon and carbon dioxide are two commonly used shielding gases in welding. Argon is an inert
gas that is often used for TIG (tungsten inert gas) welding, while carbon dioxide is commonly
used in MIG (metal inert gas) welding (Huang, 2010). The composition and mixing ratios of
these gases can vary depending on the type of welding process and the material being welded.
ii. For TIG welding, argon is typically used as a pure gas with a composition of 100% argon. This
is because argon is an inert gas that does not react with the molten weld pool, providing excellent
protection against atmospheric contamination (Babu et al., 2015). However, in some cases, a
small amount of helium may be added to improve arc stability and penetration.
iii. In MIG welding, carbon dioxide is often used in combination with argon. The most common
mixing ratio for MIG welding is 75% argon and 25% carbon dioxide. This mixture provides a
good balance of arc stability and penetration, making it suitable for a wide range of materials and
welding applications (Achekuogene et al., 2021).
It is important to note that the composition and mixing ratios of shielding gases can vary
depending on the specific requirements of the welding process. Factors such as material
thickness, welding position, and desired weld penetration can all influence the choice of shielding
gas and its composition. Compositions and mixing ratios for different weld shielding gases play a
critical role in determining the quality and efficiency of the welding process. By understanding
the properties of different gases and their effects on the weld, welders can make informed
decisions to achieve optimal weld quality. It is essential to carefully consider the specific
requirements of the welding process and select the appropriate shielding gas and mixing ratio to
ensure successful weld outcomes.
6. Colour Coding and Types of Shielding Gases
One of the key components in welding is the shielding gas, which plays a vital role in protecting
the weld pool from atmospheric contamination. In accordance with DIN EN 1089-3, colour
coding of shielding gas cylinders are presented in Table 1.

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Table 1: Colour coding of shielding gas cylinders in accordance with DIN EN 1089-3
Gas type Identification colour RAL. No. Illustration
Pure argon Dark green 6001

Oxygen White 9010

Forming gas Red 3000

Nitrogen/hydrogen

Helium Brown 8008

Mixture of argon/CO2 Bright green 6018

Carbon dioxide CO2 Grey 7037

Nitrogen Black 9005

Acetylene Maroon 3009

There are several types of shielding gases used in welding, each with its own composition and
characteristics. These are highlighted as follows:
i. Argon is one of the most commonly used shielding gases in welding. It is an inert gas that
provides excellent arc stability and penetration. Argon is often used in TIG (tungsten inert gas)
welding, where it helps to create a stable arc and produce high-quality welds. The composition of
argon used in welding is typically 100% pure (Kang et al., 2009).

ii. Another commonly used shielding gas is carbon dioxide (CO2). CO2 is an active gas that can
react with the molten metal to produce a cleaner weld. It is often used in MIG (metal inert gas)
welding, where it helps to increase the weld penetration and speed up the welding process
(Ebrahimnia et al., 2009). The composition of CO2 used in welding is typically around 75% CO2
and 25% argon.

iii. A mixture of argon and helium is also used as a shielding gas in welding. Helium is an inert
gas that provides higher heat input and deeper penetration compared to argon. The composition

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of argon-helium mixtures used in welding can vary, depending on the specific requirements of
the welding process (Jittavisuttiwong and Poopat, 2013).

iv. Oxygen is a reactive gas that can oxidize the weld pool if not properly controlled. It is
commonly used in oxy-fuel welding and cutting processes, where it reacts with the metal to
produce heat for melting. In welding applications, oxygen is typically used in small amounts (less
than 5%) to improve the stability of the arc and increase the welding speed (Afolalu et al., 2023).
In other word, Oxygen can be added to the shielding gas to improve the weld penetration and
increase the welding speed. However, excessive oxygen levels can lead to the formation of
oxides in the weld, resulting in poor weld quality and reduced mechanical properties.

v. Nitrogen, on the other hand, is an inert gas that does not react with the metal during the
welding process. It is commonly used in gas metal arc welding (GMAW) and gas tungsten arc
welding (GTAW) processes to provide a stable arc and protect the weld pool from atmospheric
contamination (Lathabai et al, 2001). It is sometimes used in stainless steel welding to prevent
oxidation and improve the weld quality. Nitrogen is typically used in concentrations of less than
10% in shielding gas mixtures to improve arc stability and reduce spatter. However, high
nitrogen levels can lead to porosity in the weld and reduce the mechanical properties of the joint.

vi. Helium is a noble gas that has been widely used as a shielding gas in welding processes. It is
known for its high thermal conductivity, which allows for efficient heat transfer during welding.
This property makes helium an ideal choice for welding applications where high heat input is
required. One of the key benefit of using helium as a shielding gas is its ability to provide
excellent arc stability. This is crucial in welding processes where precise control of the arc is
necessary to achieve high-quality welds. Helium also has a high ionization potential, which
means that it can easily ionize and create a stable arc during welding. In addition to its arc
stability, helium also offers superior penetration capabilities compared to other shielding gases.
This is particularly important in welding thick materials or when deep penetration is required.
The high thermal conductivity of helium allows for better control of the weld pool and helps
prevent defects such as lack of fusion or incomplete penetration. Furthermore, helium is non-
reactive and does not form harmful oxides or nitrides during the welding process. This makes it a
clean and environmentally friendly option for shielding gas in welding applications. Additionally,

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helium is non-flammable and non-toxic, making it a safe choice for use in welding operations
(Rao et al., 2010; Murphy and Lowke, 2018).
The choice of shielding gas in welding depends on the specific requirements of the welding
process, such as the type of metal being welded, the welding technique used, and the desired weld
quality. Understanding the composition and characteristics of different shielding gases is
essential for achieving high-quality welds in various welding applications. It is important for
welders to carefully control the composition of shielding gas mixtures to ensure high-quality
welds with the desired mechanical properties.

7. Factors Affecting the Performance of Weld Shielding Gases

Shielding gases play a vital role in the protection of molten weld pool from atmospheric
contamination, which can lead to defects such as porosity, cracking, and lack of fusion. The
performance of weld shielding gases can be affected by several factors, including gas
composition, flow rate, and purity (Shi et al., 2018). Factors affecting the performance of weld
shielding gases are as follows:
i. One of the key factors that can affect the performance of weld shielding gases is gas
composition. Different gases have different properties that can influence the welding process. For
example, argon is commonly used as a shielding gas for TIG welding because of its inert nature
and ability to provide good arc stability (Cai et al., 2017). On the other hand, carbon dioxide is
often used in MIG welding to improve penetration and reduce spatter. The choice of gas
composition should be based on the specific requirements of the welding process and the material
being welded.

ii. Another factor that can impact the performance of weld shielding gases is the flow rate. The
flow rate of the shielding gas must be carefully controlled to ensure proper coverage of the weld
pool and effective protection from atmospheric contamination (Yang et al., 2019). Insufficient
gas flow can result in inadequate shielding, leading to defects in the weld. On the other hand,
excessive gas flow can cause turbulence in the weld pool, resulting in poor weld quality. It is
important to optimize the flow rate of the shielding gas to achieve the desired welding results.

iii. Purity is also a critical factor that can affect the performance of weld shielding gases.
Impurities in the shielding gas can lead to contamination of the weld pool and result in defects in
the weld (Chuaiphan and Srijaroenpramong, 2020). It is essential to use high-purity gases to

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ensure the quality of the weld. Gas cylinders should be properly maintained and stored to prevent
contamination and ensure the purity of the shielding gas.
However, weld shielding gases affects the material transfer (coarse or fine droplets), surface
tension, and flow in the weld pool. The penetration and spattering are also greatly affected by
shielding gas. The performance of weld shielding gases can be affected by various factors,
including gas composition, flow rate, and purity. It is essential to carefully consider these factors
when selecting and using shielding gases to achieve high-quality welds. By understanding and
optimizing these factors, welders can improve the performance and efficiency of their welding
processes.
8. Selection of Suitable Weld Shielding Gases
Welding is a crucial process in various industries, and the selection of suitable shielding gases is
essential to ensure the quality and integrity of the weld. Shielding gases are used to protect the
molten weld pool from atmospheric contamination, which can lead to defects such as porosity,
cracking, and lack of fusion. The choice of shielding gas depends on several factors, including
the type of metal being welded, the welding process used, and the desired weld properties (Kah
and Martikainen, 2013). Criteria for selection of suitable weld shielding gases are as follows:
i. One of the key criteria for selecting a suitable shielding gas is the type of metal being welded.
Different metals have different chemical properties and react differently to various shielding
gases (Tukahirwa and Wandera, 2023). For example, carbon steel is commonly welded using a
mixture of argon and carbon dioxide, while stainless steel is often welded using pure argon or a
mixture of argon and helium. It is important to consider the reactivity of the metal with the
shielding gas to prevent any adverse reactions that could affect the quality of the weld.

ii. Another important criterion is the welding process being used. Different welding processes,
such as gas metal arc welding (GMAW), gas tungsten arc welding (GTAW), and flux-cored arc
welding (FCAW), require different shielding gases to achieve optimal results (Bitharas et al.,
2018). For example, GMAW typically uses a mixture of argon and carbon dioxide, while GTAW
often uses pure argon or a mixture of argon and helium. It is essential to select a shielding gas
that is compatible with the specific welding process being used to ensure proper shielding and
weld quality.

iii. The desired weld properties must be considered when selecting a shielding gas. Different
shielding gases can affect the weld penetration, bead shape, and overall weld quality (Khrais et

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al., 2023). For example, a shielding gas with high argon content can provide better arc stability
and weld penetration, while a shielding gas with high carbon dioxide content can improve weld
bead shape and reduce spatter. It is important to determine the desired weld properties and select
a shielding gas that can help achieve those goals.
The selection of suitable shielding gases for welding is a critical decision that can impact the
quality and integrity of the weld. By considering factors such as the type of metal being welded,
the welding process used, and the desired weld properties, welders can choose the most
appropriate shielding gas for their specific application. Proper selection of shielding gases can
help prevent defects and ensure high-quality welds, ultimately leading to successful welding
operations.

9. Effects of Weld Shielding Gases on Welding Operators

Welding is a common industrial process that involves joining materials together using heat. One
important aspect of welding is the use of shielding gases, which are used to protect the weld pool
from atmospheric contamination. While shielding gases are essential for achieving high-quality
welds, they can also have a range of health, environmental, economic, occupational, and hazard
effects on welding operators which are highlighted as follows (Kah and Martikainen, 2013):
i. One of the primary health effects of welding shielding gases is the potential for exposure to
toxic fumes and gases. Some shielding gases, such as argon and carbon dioxide, can produce
harmful fumes when they are heated during the welding process. Prolonged exposure to these
fumes can lead to respiratory problems, eye irritation, and other health issues for welding
operators.

ii. In terms of environmental effects, the use of shielding gases can contribute to air pollution.
When shielding gases are released into the atmosphere during welding, they can react with other
pollutants to form smog and other harmful substances. This can have negative impacts on air
quality and contribute to climate change.

iii. From an economic perspective, the cost of shielding gases can be a significant factor for
welding operators. Some shielding gases, such as helium, can be expensive to purchase and use.
This can increase the overall cost of welding operations and impact the profitability of welding
businesses.

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iv. In terms of occupational effects, welding operators are at risk of injury from handling and
using shielding gases. Improper handling of shielding gases can lead to leaks, spills, and other
accidents that can result in burns, explosions, and other serious injuries. Additionally, welding
operators may be exposed to hazards such as fire and explosion risks when working with
shielding gases.
The use of welding shielding gases can have a range of effects on welding operators, including
health, environmental, economic, occupational, and hazard effects. It is important for welding
operators to be aware of these potential effects and take appropriate precautions to minimize
risks. This may include using proper ventilation, wearing protective equipment, and following
safety guidelines for handling and using shielding gases. By addressing these issues, welding
operators can help to ensure a safe and healthy work environment for themselves and their
colleagues.

10. Applications of Weld Shielding Gases in Welding Operations

Weld shielding gases play a crucial role in various industrial, manufacturing, fabrication,
production, automotive, and mechanical applications. These gases are used to protect the molten
weld pool from atmospheric contamination, ensuring high-quality welds with minimal defects.
Applications of weld shielding gases in welding operations are as follows:
i. In industrial settings, weld shielding gases are commonly used in processes such as gas metal
arc welding (GMAW) and gas tungsten arc welding (GTAW). These gases, such as argon,
helium, and carbon dioxide, create a protective atmosphere around the weld pool, preventing
oxidation and other forms of contamination that can weaken the weld joint (Kumar et al., 2014).
This is particularly important in industries where weld integrity is critical, such as aerospace,
automotive, and construction.

ii. In manufacturing and fabrication, weld shielding gases are essential for producing high-quality
welds with consistent mechanical properties. By controlling the composition of the shielding gas,
welders can tailor the welding process to meet specific requirements, such as strength, ductility,
and corrosion resistance (Sallam et al., 2010). This level of control is crucial in industries where
weld quality directly impacts the performance and safety of the final product.

iii. In production environments, weld shielding gases are used to increase efficiency and reduce
costs. By creating a stable arc and improving weld penetration, these gases allow for faster

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welding speeds and higher deposition rates (Campbell et al., 2012). This can lead to significant
time and cost savings, making weld shielding gases a valuable tool for manufacturers looking to
improve their bottom line.
iv. In automotive applications, weld shielding gases are used in a variety of processes, including
resistance spot welding, laser welding, and robotic welding. These gases help to create strong,
durable welds that can withstand the rigors of automotive use, ensuring the safety and reliability
of the vehicle (Graudenz and Baur, 2013). Additionally, weld shielding gases can improve the
aesthetics of the weld joint, creating a clean, smooth finish that enhances the overall appearance
of the vehicle.
v. In mechanical applications, weld shielding gases are used to join a wide range of materials,
from steel and aluminium to exotic alloys and composites. By selecting the appropriate shielding
gas for the specific material and welding process, engineers can achieve strong, durable welds
that meet the performance requirements of the application (Fortain and Gadrey, 2013). This level
of precision and control is essential in industries where weld quality is critical to the overall
functionality of the product.
Weld shielding gases play a vital role in a wide range of industrial, manufacturing, fabrication,
production, automotive, and mechanical applications. By creating a protective atmosphere around
the weld pool, these gases ensure high-quality welds with minimal defects, improving the
strength, durability, and performance of the final product. As such, weld shielding gases are an
essential tool for achieving optimal welding results in a variety of industries.
11. Advantages of Weld Shielding Gases in Welding Operations
Weld shielding gases play a crucial role in welding applications by providing a protective
atmosphere around the weld pool. This helps to prevent oxidation and contamination of the weld,
resulting in high-quality and strong welds. The advantages and benefits of using weld shielding
gases in welding operations are highlighted as follows:
i. One of the main advantages of using shielding gases in welding is the ability to control the
weld pool and the heat input. By using the appropriate shielding gas, welders can achieve the
desired penetration and fusion without causing excessive heat distortion or warping of the base
metal (Mvola and Kah, 2017). This results in a more precise and controlled welding process,
leading to higher quality welds.
ii. Another benefit of using shielding gases is the ability to improve the overall weld quality. By
creating a protective atmosphere around the weld pool, shielding gases help to prevent the

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formation of porosity, slag inclusions, and other defects in the weld (Zhang et al., 2021). This
results in stronger and more reliable welds that meet the required specifications and standards.
iii. Shielding gases can also improve the efficiency and productivity of the welding process. By
using the right combination of shielding gases, welders can increase the welding speed and
deposition rate, leading to faster production times and reduced labour costs (Li et al., 2023). This
can be especially beneficial in high-volume welding applications where time and cost savings are
essential.
iv. Using shielding gases can also help to reduce the need for post-weld cleaning and finishing.
By creating a clean and controlled welding environment, shielding gases minimize the formation
of spatter and slag, making it easier to produce clean and smooth welds that require minimal post-
welding clean-up (Trydell and Holgersson, 2019). This can save time and resources, as well as
improve the overall aesthetics of the weld.
The advantages and benefits of using weld shielding gases in welding applications are clear.
From improving weld quality and efficiency to reducing defects and post-weld clean-up,
shielding gases play a crucial role in ensuring successful and reliable welding operations.
Therefore, it is essential for welders to understand the importance of using the right shielding
gases and to incorporate them into their welding processes for optimal results.
12. Disadvantages of Weld Shielding Gases in Welding Operations
Despite the advantages of weld shielding gases in the welding operations, these gases also come
with a number of disadvantages and limitations that can impact the quality and efficiency of the
welding operation. Disadvantages of weld shielding gases in welding operations include the
following:
i. One of the main disadvantages of weld shielding gases is their cost. In many cases, these gases
can be expensive to purchase and maintain, especially for large-scale welding operations. This
cost can add up quickly, particularly for businesses that rely heavily on welding as part of their
manufacturing process.

ii. Another limitation of weld shielding gases is their potential impact on the environment. Many
of these gases are classified as greenhouse gases, which can contribute to climate change and
other environmental issues. In addition, the production and transportation of these gases can also
have a negative impact on the environment.

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iii. Weld shielding gases can be difficult to work with in certain situations. For example, some
gases may require special handling or storage procedures to ensure their safety and effectiveness.
This can add an extra layer of complexity to the welding process and may require additional
training for welders.

vi. Some weld shielding gases may not be suitable for all types of welding applications. Certain
gases may be more effective for specific materials or welding techniques, while others may not
provide adequate protection or may even cause defects in the weld.
While weld shielding gases are an essential component of the welding process, it is important to
be aware of their limitations and disadvantages. By understanding these factors, welders can
make informed decisions about the use of shielding gases and take steps to mitigate any potential
drawbacks.

13. Conclusion and Recommendations

This study was conducted to determine the effectiveness of different shielding gases in achieving
high-quality welds. Based on the findings obtained, several conclusions have been drawn
regarding the use of shielding gases in welding applications. Firstly, the choice of shielding gas
significantly impacts the quality of the weld. This study have that inert gases such as argon and
helium are commonly used for shielding in TIG welding, as they provide excellent protection
against oxidation and produce clean, high-quality welds. On the other hand, active gases like
carbon dioxide are often used in MIG welding to improve penetration and increase welding
speed. It is essential for welders to carefully select the appropriate shielding gas based on the
specific requirements of the welding process. Secondly, the composition of the shielding gas
mixture can also affect the weld quality. In the course of this study, it was observed that gas
mixtures containing a combination of inert and active gases can offer the benefits of both types of
gases, such as improved weld penetration and reduced spatter. Additionally, the addition of small
amounts of reactive gases like oxygen or nitrogen can enhance the weld properties by promoting
better wetting and reducing porosity. Furthermore, the flow rate and distribution of the shielding
gas are critical factors in ensuring proper weld protection. Insufficient gas flow can lead to
inadequate shielding, resulting in defects such as porosity and lack of fusion. Proper gas flow
rates and distribution patterns must be maintained to achieve consistent and high-quality welds.
The present findings on weld shielding gases have provided valuable insights into the
effectiveness of different gases in protecting the weld pool from atmospheric contamination.

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Based on these findings, the following recommendations have been made to optimize the use of
shielding gases in welding processes.
i. It is important to consider the specific requirements of the welding process when selecting a
shielding gas. Different gases have varying levels of reactivity and thermal conductivity, which
can impact the quality of the weld. For example, inert gases such as argon are commonly used for
TIG welding because they provide excellent protection against oxidation, while active gases like
CO2 are often used for MIG welding to improve penetration and weld strength.

ii. This study revealed that a mixture of gases can often provide better results than using a single
gas. For example, a combination of argon and CO2 has been found to improve weld quality and
reduce spatter compared to using CO2 alone. By experimenting with different gas mixtures,
welders can tailor their shielding gas to meet the specific requirements of the welding process.

iii. It is important to ensure that the shielding gas is delivered to the weld pool in an efficient
manner. Recent studies have shown that using a gas flow rate that is too high or too low can
result in poor weld quality. By carefully adjusting the gas flow rate and nozzle position, welders
can ensure that the shielding gas effectively protects the weld pool without causing excessive
turbulence or gas wastage.
Therefore, this study highlights the importance of selecting the proper weld shielding gas,
experimenting with gas mixtures, and optimizing gas delivery for optimal weld quality. By
following these recommendations, welders can improve the efficiency and effectiveness of their
welding processes, leading to higher quality welds and reduced rework.

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