College of Industrial technology

Department of Welding Technology &

Engineering

Asst.Prof. Manoon Lertvijitpun & Surachet Kaewngam

Tel. 66-081 828 1564 Email: manoonlp@gmail.com
 1.6 Introduction to gas shielded arc welding (2hrs.)
Objective: Understand in detail the principles and physical phenomena of gas shielded
welding processes.

Scope:
Physical phenomena ……………………………………………………...…….
Shielding gases (inert, active) and their effect on arc characteristics ….….
Handling and storage of gases (overview)…………………………..………..
Influence of the welding parameters on the weld bead morphology...…..…
Standards (ISO, CEN and National) for shielding gases…………..…...…...

Learning Outcomes:
1. Explain fully the characteristics and operating principles of TIG, MIG/MAG and
Flux-cored welding.
2. Interpret arc characteristics associated with each type of shielding gas used for
each process.
3. Detail the methods for safe handling and storage of shielding gases.
4. Interpretation and use of standards for shielding gases and filler materials.
Typical cost breakdown for MAG welding

Carbon Steel Stainless Steel

 Gas Tungsten Arc welding (14)

Process numbers according to DIN EN ISO 4063

Tungsten-inert-gas welding with solid wire or rod 141
Tungsten-inert-gas welding without filler wire or rod 142
Tungsten-inert-gas welding with flux cored wire or rod 143
Tungsten-inert-gas welding with solid wire or rod with deoxidizing gas
(partly) 145
 Plasma Arc Welding (15)

Plasma Arc Welding 15

Plasma MIG Welding 151
Powder Plasma Arc Welding 152
Plasma Arc Welding with transferred arc 153
Plasma Arc Welding with non-transferred arc 154
Plasma Arc Welding with semi-transferred arc 155
 Gas shielded Metal Arc welding

Process numbers according to DIN EN ISO 4063

Metal-active gas welding with solid wire 135
Metal-active gas welding with flux cored wire 136
Metal-active gas welding with metal cored wire 138
Metal-inert gas welding with solid wire 131
Table 1: Designations and process types for the MIG/MAG welding process
Code According
Short Remarks
Welding Process to
Symbol
ISO 4063
Gas-Shielded Metal Arc Welding GMAW 13 Generic term
Metal-arc inert gas welding with Inert shielding gas (argon, helium and
MIG 131
solid wire electrode argon/helium Mixtures)
Metal-arc inert gas welding Inert shielding gas (argon, helium and
MIG 132
with flux-cored wire electrode argon/helium mixtures)
Metal-arc inert gas welding with Inert shielding gas (argon, helium and
MIG 133
metal powder-filled wire electrode argon/helium mixtures)
Metal-arc active gas welding with Argon-filled gas mixes or 100% CO2
MAG 135
solid wire electrode
Metal-arc active gas welding with
MAG 136 Argon-filled gas mixes or 100% CO2
flux-cored wire electrode
Metal-arc active gas welding with Argon-filled gas mixes or 100% CO2
MAG 138
metal powder-filled wire electrode
CO2 welding MAGC -------- Shielding gas 100% CO2
Mixed gas welding MAGM -------- Argon-filled gas mixes
Self-shielded flux-cored arc MF With self-protecting cored-wire
114
welding electrodes
Hybrid Welding (PAW + MIG)
 Schematic view of plasma – Schematic view of plasma –
GSMA welding GSMA welding
with concentric arranged plasma arc. with both arcs being arranged in series.
 Gas-shielded Arc Welding Process

Gas-shielded Metal Gas-shielded Tungsten

Arc Welding Arc Welding

Metal Inert Gas Electric Gas TIG PAW

Welding with Welding Tungsten Inert Plasma Arc
flux core wire Gas Welding Welding
Plasma Beam
Metal Active
Welding
Gas Welding
with flux core wire Plasma Metal
Plasma Arc Gas-shielded Welding
MIG Welding
Plasma Jet Arc Welding
Metal Inert
Gas Welding
Powder Plasma Welding
MAG-C
MAG CO2 Welding
Metal Active
Gas Welding
MAG-M
Gas mixture Welding
Inert:
Active  Oxidizing, Reducing, Chemical Combination
Table 1 — Properties of gas components
 สมบัติสำคัญของแก๊สปกป้องในกำรเชื่อมและตัด
[Shielding gases for welding and cutting]

ิ า(เคมี)ในขณะเชือ่ ม [How they react during welding (inert,

1) การทาปฎิกริ ย
oxidizing, slow-reacting, reducing) Density (heavier/lighter than air)]

2) สมบัติกายภาพทางความร้ อนเช่ นการนาความร้ อน [Thermal conductivity

and capacity]

3) พลังงานในการสลายพันธะเคมี [Ionization/dissociation energy and hence in

the arc voltage, in relation to a given arc length]

4) จุดเดือด [Boiling point]

 สมบัติสาคัญของแก๊สปกป้อง
[Requirements for shielding gases]

แก๊ สปฎิกริ ิยา [Active]

 [Shielding gases are gases which cause the arc to
interact chemically and physically with the filler and base
material.]

แก๊ สเฉื่ อย [Inert]

 [Shielding gases are gases which do not enter into
chemical reactions during welding.]
  Oxidation is gain of oxygen.  Reduction is loss of oxygen.
Both reduction and oxidation are going on side-by-side,
this is known as a redox reaction.

Magnesium is reducing the copper(II) ions by giving them electrons to

neutralise the charge. Magnesium is a reducing agent.
Copper(II) ions are removing electrons from the magnesium to create the
magnesium ions. The copper(II) ions are acting as an oxidising agent.
  Oxidation is gain of oxygen.  Reduction is loss of oxygen.
Both reduction and oxidation are going on side-by-side,
this is known as a redox reaction.

Oxidation Agent: สารทีท

่ าหน้ าที่รับอิเล็กตรอน
Reducing Agent: สารทีท
่ าหน้ าที่เป็ นตัวให้ อิเล็กตรอน
  Oxidation is gain of oxygen.  Reduction is loss of oxygen.
Both reduction and oxidation are going on side-by-side,
this is known as a redox reaction.
ปฏิกริ ิยาออกซิเดชัน (oxidation) หมำยถึงปฏิกิริยำที่โมเลกุลหรืออะตอมมีกำรสู ญเสีย
อิเล็กตรอนจากวงโคจรให้กบั โมเลกุลที่ทำหน้ำที่เป็ นตัวรับอิเล็กตรอน
ปฏิกิริยำออกซิ เดชันและรีดกั ชัน (reduction) จะเกิดคู่กนั สารทีท่ าหน้ าทีเ่ ป็ นตัวให้ อิเล็กตรอน
เรียกว่ า ตัวรีดวิ ซ์ (reducing agent) และเรียกสารทีท่ าหน้ าทีร่ ับอิเล็กตรอนนี้วำ่ ตัวออกซิไดส์ (oxidizing
agent) โดยปฏิกิริยำออกซิ เดชัน มักจะเกี่ยวข้องกับออกซิ เจน

นอกจำกนี้ออกซิเดชันยังหมายถึงการเสียไฮโดรเจนอะตอมออกจากโมเลกุลอีกด้ วย ปฏิกิริยำ
ออกซิ เดชันและอนุมูลอิสระนั้นมีควำมเกี่ยวข้องกัน เนื่องจำกปฏิกิริยำนี้ทำให้เกิดอนุมูลอิสระ
ของสำรต่ำงๆ ได้มำกมำยหลำยชนิ ด และอนุมูลอิสระที่เกิดขึ้นจะทำให้เกิดปฏิกิริยำออกซิ เดชัน
กับสำรอื่นๆ เป็ นปฏิกิริยำลูกโซ่ต่อไป
อะตอมที่ทาหน้ าทีเ่ ป็ น reducing agent ได้ดี เป็ นอะตอมที่มีขนาดใหญ่ จึงมีระยะห่ างระหว่ าง
นิวเคลียส กับอิเล็กตรอนวงนอกสุ ดมาก จึงมีแรงดึงดูดอิเล็กตรอน (electronegativity) ต่า ทำให้สูญเสี ย
อิเล็กตรอนง่ำย
 Core elements and their function
Aluminium - deoxidize & denitrify
Calcium - provide shielding & form slag
Carbon - increase hardness & strength
Manganese - deoxidize & increase strength and toughness
Molybdenum - increase hardness & strength
Nickel - improve hardness, strength, toughness & corrosion
resistance
Potassium - stabilize the arc & form slag
Silicon - deoxidize & form slag
Sodium - stabilize arc & form slag
Titanium - deoxidize, denitrify & form slag

4/23/2007 18 of 691
 Metal Active Gas (MAG)

Wire Wire not alloyed with Wire alloyed with

Si + Mn Si + Mn
Arc CO2  CO + O CO2  CO + O
O + Fe  FeO O + Fe  FeO
Molten Bath FeO + C  Fe + CO 2FeO + Si  Fe + SiO2
(Porosity) FeO + Mn  Fe + MnO

(Light Slag)
 General requirements
 Suitability for all types of arcs
 Sufficient shielding effect depending on place of use
and type of weld
 Favorable melt flow characteristics
 Not sensitive to impurities in the weld seam area
 Can be used for all wire diameters
 Slag formation and/or distribution over the weld surface
 Resistance to pore formation
 Prevention of weld spatter
 Physical requirements:

 Ignition behavior at start of welding

 Arc stability, i.e. constant arc
 Arc shorting out and re-igniting
 Plasma formation/electrical conductivity
 Dissolution characteristics depending on the material
 Degassing characteristics
 Thermal requirements:
 Heat conductivity
 Heat capacity
 Heat transfer capacity, i.e. heat transfer coefficient

Metallurgical requirements:
 Element pick-up
 Element burn-off
 Preservation of mechanical-topological characteristics
 Preservation of corrosion-resistance characteristics
 Properties of (Single) shielding gases

Table 1: Gas characteristics to DIN EN ISO 14175

Gas Chem. Specific characteristics Reaction
symbol (s) at 0 °C and 1.013 bar behaviour
(0.101 MPa) during welding
Density Relative Boiling
(air = 1.293) density to air point [°C]
[kg/m³]
Argon Ar 1.784 1.380 - 185.9 Inert
Helium He 0.178 0.138 - 268.9 Inert
Carbon dioxide CO2 1.977 1.529 - 75.51) Oxidizing
Oxygen O2 1.429 1.105 - 183.0 Oxidizing
Nitrogen N2 1.251 0.968 - 195.8 Slow-reacting2)
Hydrogen H2 0.090 0.070 - 252.8 Reducing
1) Sublimation temperature
2) Nitrogen behaves differently with different materials, and the effects may be adverse.
 Shielding gases for TIG welding
Argon
• low cost and greater availability
• heavier than air - lower flow rates than Helium
• low thermal conductivity - wide top bead profile
• low ionisation potential - easier arc starting, better arc
stability with AC, cleaning effect
• for the same arc current produce less heat than helium -
reduced penetration, wider HAZ
• to obtain the same arc arc power, argon requires a higher
current - increased undercut

4/23/2007 24 of 691
 Shielding gases for TIG welding
Helium
• costly and lower availability than Argon
• lighter than air - requires a higher flow rate compared with
argon (2-3 times)
• higher ionisation potential - poor arc stability with AC, less
forgiving for manual welding
• for the same arc current produce more heat than argon -
increased penetration, welding of metals with high melting
point or thermal conductivity
• to obtain the same arc arc power, helium requires a lower
current - no undercut

4/23/2007 25 of 691
 Shielding gases for TIG welding
Hydrogen
• not an inert gas - not used as a primary shielding gas
• increase the heat input - faster travel speed and increased
penetration
• better wetting action - improved bead profile
• produce a cleaner weld bead surface
• added to argon (up to 5%) - only for austenitic stainless steels
and nickel alloys
• flammable and explosive

4/23/2007 26 of 691
 Shielding gases for TIG welding

Nitrogen
• not an inert gas
• high availability - cheap
• added to argon (up to 5%) - only for back purge for duplex stainless,
austenitic stainless steels and copper alloys
• not used for mild steels (age embrittlement)
• strictly prohibited in case of Ni and Ni alloys (porosity)

4/23/2007 27 of 691
Heat conductivity of shielded gas constituents (according to Linde)
 Classification and designation of shielding
gases to DIN EN ISO 14175
Main group:
— I: inert gases and gas mixtures;
— M1, M2 and M3: oxidizing gas mixtures with oxygen and/or
carbon dioxide;
— C: highly oxidizing gases and gas mixtures;
— R: reducing gas mixtures;
— N: slow-reacting gas or gas mixture with nitrogen;
— O: oxygen;
— Z: gas mixtures with constituents which are not included in Table 3
or gas mixtures whose compositions are outside the ranges stated
in Table 3.
 Table 3: Classification of process gases for welding joints and related processes (1)
Symbol Constituents in percent by volume (nominal)
Low
Main oxidizing inert Reducing
Subgroup reactivity
group
CO2 O2 Ar He H2 N2
1 ----------------- ----------------- 100 ------------------ -------------- -----------------

I 2 ----------------- ----------------- 100 ------------------ -------------- -----------------

3 ----------------- ----------------- Rest 0.5 ≤ He ≤ 95 -------------- -----------------

0.5 ≤ H2 ≤ 5
1 0.5 ≤ CO2 ≤ 5 ----------------- Resta -------------- -----------------

Resta
2 0.5 ≤ CO2 ≤ 5 ----------------- ------------------ -------------- -----------------
M1
3 ----------------- 0.5 ≤ O2 ≤ 3 Resta ------------------ -------------- -----------------

4 0.5 ≤ CO2 ≤ 5 0.5 ≤ O2 ≤ 3 Resta ------------------ -------------- -----------------

a For the purpose of this classification, argon may be substituted partially or completely with helium.
b Two gas mixtures with the same Z classification must not be interchanged.
Table 3: Classification of process gases for welding joints and related processes (2)
Symbol Constituents in percent by volume (nominal)
Low
Main oxidizing inert Reducing
Subgroup reactivity
group
CO2 O2 Ar He H2 N2
0 5 < CO2 ≤ 15 ---------------- Resta -------------- -------------- -----------------

1 15 < CO2 ≤ 25 ---------------- Resta -------------- -------------- ----------------

3 < O2 ≤ 10
2 ---------------- Resta -------------- -------------- -----------------

3 0.5 ≤ CO2 ≤ 5 3 < O2 ≤ 10 Resta -------------- -------------- -----------------

M2
4 5 < CO2 ≤ 15 0.5 ≤ O2 ≤ 3 Resta -------------- -------------- -----------------

5 5 < CO2 ≤ 15 3 < O2 ≤ 10 Resta -------------- -------------- -----------------

6 15 < CO2 ≤ 25 0.5 ≤ O2 ≤ 3 Resta -------------- -------------- -----------------

7 15 < CO2 ≤ 25 3 < O2 ≤ 10 Resta -------------- -------------- -----------------

a For the purpose of this classification, argon may be substituted partially or completely with helium.
b Two gas mixtures with the same Z classification must not be interchanged.
 Table 3: Classification of process gases for welding joints and related processes (1)
Symbol Constituents in percent by volume (nominal)
Low
Main oxidizing inert Reducing
Subgroup reactivity
group
CO2 O2 Ar He H2 N2
1 25 < CO2 ≤ 50 ---------------- Resta ---------- ------------ ------------
2 ---------------- 10 < O2 ≤ 15 Resta ---------- ------------ ------------

M3 3 25 < CO2 ≤ 50 2 < O2 ≤ 10 Resta ---------- ------------ ------------

4 5 < CO2 ≤ 25 10 < O2 ≤ 15 Resta ---------- ------------ ------------
5 25 < CO2 ≤ 50 10 < O2 ≤ 15 Resta ---------- ------------ ------------
1 100 ------------ ---------- ------------ ------------
C 2 Rest 0.5 ≤ O2 ≤ 30 ------------ ---------- ------------ ------------
1 ------------ ------------ Resta ---------- 0.5 ≤ H2 ≤ 15 ------------
R 2 ------------ ------------ Resta ---------- 15 < H2 ≤ 50 ------------

a For the purpose of this classification, argon may be substituted partially or completely with helium.
b Two gas mixtures with the same Z classification must not be interchanged.
Table 3: Classification of process gases for welding joints and related processes (2)
Symbol Constituents in percent by volume (nominal)
Low
Main oxidizing inert Reducing
Subgroup reactivity
group
CO2 O2 Ar He H2 N2
1 ----------------------------- -------------------- ----------------- ----------- -------------------- 100
2 ----------------------------- -------------------- Resta ----------- -------------------- 0.5 ≤ N2 ≤ 5
3 Resta ----------- -------------------- 5 < N2 ≤ 50
N ----------------------------- --------------------

0.5 ≤ N2 ≤ 5
4 ----------------------------- -------------------- Resta ----------- 0.5 ≤ H2 ≤ 10

5 ----------------------------- -------------------- ----------- ----------- 0.5 ≤ H2 ≤ 50 Rest

O 1 ----------------------------- 100 ----------- ----------- -------------------- -----------------

Gas mixtures with constituents which are not included in the table or gas mixtures whose compositions
Z are outside the ranges indicated.b

a For the purpose of this classification, argon may be substituted partially or completely with helium.
b Two gas mixtures with the same Z classification must not be interchanged.
 Properties of (Mixed) shielding gases
Table 2: Density and correction factor depending on the helium part in
argon based shielding gases
Gas, / gas mixtures
flow-reading
Density Correction factor
multiplied with
At 15°C, 1 bar
[kg/m3]
100% Argon 1,78 1,00
75% Ar + 25% He 1,29 1,14
50% Ar + 50% He 0,92 1,35
25% Ar + 75% He 0,54 1,75
100% He 0,17 3,16

Correction Actual
Gas Flow-reading
factor gas flow
25% Ar + 75% He 12 l/min 1,75 21 l/min
 Classification of Shielding Gases to
DIN EN ISO 14175

EXAMPLE 1
 Gas mixed (Ar+6%CO2+4%O2) : ISO 14175  M25

EXAMPLE 2
 Gas mixed (Ar + 30%He ): ISO 14175  I3

EXAMPLE 3
 Gas mixed (Ar + 5%H2): ISO 14175  R1

EXAMPLE 4
 Gas mixed (Ar + 0.05%O2): ISO 14175  Z
 Classification and designation of Shielding Gases
to DIN EN ISO 14175
The base gas symbol must be followed by the symbols for the
other constituents in decreasing order of percentage content
followed by the values for the nominal composition in per
cent by volume, separated by a dash.
EXAMPLE 1 Gas mixture with 6% carbon dioxide, 4% oxygen and rest
argon (Ar+6%CO2+4%O2)
Classification: ISO 14175 – M25
Designation: ISO 14175 – M25 – ArCO – 6/4

EXAMPLE 2 Gas mixture with 30% helium and rest argon (Ar + 30%He )
Classification: ISO 14175 – I3
Designation: ISO 14175 – I3 – ArHe – 30
 Classification and designation of Shielding Gases
to DIN EN ISO 14175
EXAMPLE 1 Gas mixture with 6% carbon dioxide, 4% oxygen and rest
argon (Ar+6%CO2+4%O2)
Classification: ISO 14175 – M25
Designation: ISO 14175 – M25 – ArCO – 6/4

EXAMPLE 2 Gas mixture with 30% helium and rest argon (Ar + 30%He )
Classification: ISO 14175 – I3
Designation: ISO 14175 – I3 – ArHe – 30

EXAMPLE 3 Gas mixture with 5% hydrogen and rest argon (Ar + 5%H2)
Classification: ISO 14175 – R1
Designation: ISO 14175 – R1 – ArH – 5
EXAMPLE 4 Gas mixture with 7.5% argon, 2.5% carbon dioxide and the
rest helium:(He + 7.5%Ar + 2.5%O2)
Classification: ISO 14175 – M12
Designation: ISO 14175 – M12 – HeArC – 7.5/2.5
 Classification and designation of Shielding Gases
to DIN EN ISO 14175
For mixed gas mixtures with constituents listed in Table 3 but whose
contents are outside the ranges stated, the base gas symbol must be
preceded by the letter Z.
This is followed by the symbols for the components as stated above,
followed by the values for the nominal composition in percentage by
volume, separated by a forward slash.

EXAMPLE 5 Gas mixture with 0.05% oxygen and rest argon:

Classification: ISO 14175 – Z
Denomination: ISO 14175 – Z – ArO – 0.05
 Classification and designation of Shielding Gases
to DIN EN ISO 14175
For gas mixtures with constituents which are not listed in Table 3,
the base gas symbol must be preceded by the letter Z.
This is followed by the symbols for the constituents as stated above,
but with a plus sign before the constituents not listed, followed by the
values for the nominal composition in per cent by volume, separated by
a dash.

EXAMPLE 6 Gas mixture with 0.05% xenon, chemical symbol Xe, rest
argon:
Classification: ISO 14175 – Z
Designation: ISO 14175 – Z – Ar + Xe – 0.05
 Choice of Shielding Gases
Active shielding gases for MAG- welding of steel
Shielding gases which are reacting with the melting filler wire and
the weld pool are designated as active shielding gases (Metal Active-Gas
welding).

CO2 or O2 and/or CO2 portions in Active shielding gases consists CO2

or for mixture gases with high argon content, components of O2
and/or CO2.

The chemical behaviour of oxygen-emitting shielding gases is called

“oxidizing” which are mainly used for welding of steel.

Compared to welding with pure argon, welding of steel with

oxidizing, argon-rich shielding gases and pure CO2 creates fewer pores,
less undercut and a more stable arc.
Table 5: Shielding gases for TIG welding in dependency of the base material
Base material Shielding gas Root shielding gas
Non-alloyed and low-alloyed Argon N2 90% + H2 10%
steels
Austenitic CrNi-Steels Argon Argon
Ar 98% + H2 2% N2 90% + H2 10%
Ar 95% + H2 5% Ar 90% + H2 10%
high alloyed corrosion-, acid- and Argon Argon
heat resistance steels, creep- and N2 90% + H2 10%
low-temperature resistance steels Ar 90% + H2 10%
Aluminium, Al-alloys Argon 100% Argon
Copper- and Cu-alloys, Ar 75% + He 25%
Nickel and Ni-alloys Ar 50% + He 50%
Ar 25% + He 75%
Helium
Gas-sensitive alloys like Argon with purity > 4.8 Argon with purity > 4.8
Titanium, Tantalum etc.
Duplex- und Super-Duplex- Argon Argon
Steels Ar + N2 ≤ 5%
Table 6: Shielding gases for MIG/MAG welding in dependency of the base material
Base Material MIG MAG Root
Shielding Gas
Non-alloyed and ---------- Ar 92% + O2 8% --------------------
low-alloyed steels Ar 82% + CO2 18%
Ar 90% + CO2 5% + O2 5%
Ar 82% + CO2 14% + O2 4%
CO2 100%
High alloyed ---------- Ar 97% + O2 3% Argon
corrosion-, acid- Ar 98 % + CO2 2% N2 90% + H2 10%
and heat resistance Ar 69% + He 30% + O2 1% Ar 90% + H2 10%
steels, creep- and
low temperature
resistance steels
Table 6: Shielding gases for MIG/MAG welding in dependency of the base material
Base Material MIG MAG Root
Shielding Gas
Aluminium, Al- Argon 100% --------------- Argon
alloys Copper- and Ar 50% + He 50%
Cu-alloys
Nickel and Ni-lloys Argon 100% --------------- Argon
Gas-sensitive alloys Argon with purity ≥ 4.8 --------------- Argon with purity ≥ 4.8
like Titanium,
Tantalum etc.
 Shielding gas consumption and measuring
The shielding gas consumption (shielding gas flow) is determined by a
number of factors, as follows:
 The welding process and weld pool size
 The electrode size (diameter) with MIG/MAG welding
 Gas type and composition
 Size of welding torch/gas nozzle

MAG Welding  wire-diameter-size x 10-12.

Example: wire diameter =1.2mm  gas flow rate: 14 L/min.

TIG welding  The gas nozzle inside diameter:

Example: Gas nozzle inside diameter of 8mm a gas flow rate = 8 L/min.
 Gas flow consumption setting

Flow rate setting via a floating device

Measuring/setting via a
Flow-orifice
 Purity grade Impurities Containers Filling pressure Contents
O2  2 vpm L 10 S 200 bar 2.1 m3
Argon 4.8 H2O  2 vpm L 50 S 200 bar 10.7 m3
> 99.998 Vol. %
zero grade HC < 0.2 vpm ----------- ----------- -----------
CO2 < 0.2 vpm ----------- ----------- -----------
O2 < 2 vpm Pressure 12 bar 12 l
Can
N2 < 5 vpm Lecture 150 bar 62.0 l
Argon 5.0 Bottle
> 99.999 Vol. %
H2O < 3 vpm L 10 200 bar 2.1 m3
HC < 0.1 vpm L 50 200 bar 10.7 m3
CO2 < 0.1 vpm L 50 300 bar 15.3 m3
 Purity grade Impurities Containers Filling pressure Contents
H2O < 50 vpm L 10 57.3 bar 7.5 kg

Carbon Dioxide 4.0 O2 < 25 vpm L 50 57.3 bar 37.5 kg

> 99.99 Vol. %
N2 < 25 vpm L 30 57.3 bar 22.6 kg

O2 < 25 vpm Pressure 10 bar 21 g

Can
N2 < 25 vpm Lecture 57.3 bar 280 g
Bottle
Carbon Dioxide 4.5
 99.995 Vol. % HC < 1 vpm L 10 57.3 bar 7.5 kg

CO < 1 vpm L 50 57.3 bar 37.5 kg

H2O < 5 vpm L 50 * 57.3 bar 37.5 kg

*Cylinders with dip tube for liquid withdrawal

Table 2: Minimum requirements for purities and moisture contents of
gases and gas mixtures
Main Purity Dew point at Moisture content
group/gas Vol.% 0.101 MPa (volumes)
minimum °C ppm maximum
I Inert 99.99 −50 40
M1 a Gas mixture 99.9 −50 40
M2 a Gas Mixture 99.9 −44 80
M3 a Gas Mixture 99.9 −40 120
Ca Carbon dioxide 99.8 −40 120
R Reducing 99.95 −50 40
N Nitrogen 99.9 −50 40
O Oxygen 99.5 −50 40
IMPORTANT, please note: a higher purity and/or lower dew point may be advisable
for certain applications to avoid potential oxidization and contamination.
a Nitrogen: max. 1,000 ppm
 Shielding gases for TIG welding
Parent metal Shielding gas
Ferritic and martensitic 1) Ar
2) Ar + 30% He
Standard austenitic 1) Ar
(304, 316, etc.) 2) Ar + 30% He
3) Ar + 2% H2
Fully austenitic 1) Ar
(254 SMO, etc.) 2) Ar + 2% N2
3) Ar + 30% He + 2% N2
Duplex 1) Ar
(2205, SAF 2507) 2) Ar + 2% N2
3) Ar + 30% He + 2% N2
Nickel base alloys (625, 800) 1) Ar
2) Ar + 30% He
 Shielding gases for TIG welding
General guidelines:
 The gas flow for manual TIG welding is typically 4 – 8 l/min.
 The gas flow for automatic welding is higher, up to 15 l/min.
 With large diameter nozzles, gas flow should be at the high end of
the range.
 Porosity may result if the gas flow is either too low or too high.
 TIG welding is sensitive to draughts.
 Suitable draught exclusion must be provided when welding
in susceptible locations, e.g. on-site or in large, open halls.
 Shielding gases for PAW
Parent Plasma Gas Shielding Gas
Metal
Austenitic 1) Ar Ar or the same
2) Ar + 5% H2 as the plasma gas
3) Ar + 20 – 30% He
4) Ar + 20 – 30% He + 1 – 2% N2
Duplex 1) Ar Ar or the same
2) Ar + 20 – 30% He as the plasma gas
3) Ar + 20 – 30% He + 1 – 2% N2
 Shielding gases for PAW
General guidelines:
 The plasma gas flow for PAW is typically 3 – 7 l/min.
 The shielding gas flow is typically 10 – 15 l/min.
 Shielding gases for MIG welding
Parent metal Shielding gas
Ferritic and Martensitic 1. Ar + 1 – 2% O2
2. Ar + 2 – 3% CO2
Standard Austenitic 1. Ar + 1 – 2% O2
(304, 316, etc.) 2. Ar + 2 – 3% CO2
3. Ar + 30% He + 1 – 3% CO2
Fully Austenitic 1. Ar + 30% He
(254 SMO, etc.) 2. Ar + 30% He + 1 – 3% CO2
3. Ar + 30% He + 1 – 2% N2
4. Ar
Duplex 1. Ar + 1 – 2% O2
(2205, SAF 2507) 2. Ar + 2 – 3% CO2
3. Ar + 30% He + 1 – 3% CO2
Nickel Base Alloys 1. Ar + 30% He
(625, 800) 2. Ar + 30% He + 1 – 3% CO2
3. Ar
 Shielding gases for MIG welding

General guidelines:

 The gas flow for manual MIG welding is typically 12 – 16

l/min.
 The gas flow for automatic welding is higher, up to 20 l/min.
 With large diameter nozzles, gas flow should be at the high end
of the range.
 Porosity may result if the gas flow is either too low or too high.
 MIG welding is sensitive to draughts.
 When welding outdoors, suitable draught exclusion must be
provided for the weld.
 Shielding gases for FCAW
Parent metal Shielding gas
Ferritic and martensitic 1) Ar + 15 – 25% CO2
2) 100% CO2
Standard austenitic 1 1) Ar + 15 – 25% CO2
(304, 316, etc.) 2) 100% CO2
Duplex (2205) 1) Ar + 15 – 25% CO2
2) 100% CO2
 Shielding gases for FCAW
General guidelines:
 The gas flow for FCAW welding is typically 20 – 25 l/min.
 Porosity may result if the gas flow is either too low or too high.
 The gas flow should be around, or slightly below, 20 l/min
when welding in the vertical-up and overhead positions.
 A somewhat higher voltage (+3V) should be used when welding
Outokumpu 2205.
 A somewhat higher voltage (+3V) should be used when the
shielding gas is 100% CO2
 Backing Gas
 Pickling is inhibited or not possible

 Normally same as front shielding gas, employed for root runs of

single-side welds of non fluxing processes.

 The backing provides protection against oxidation, improved

corrosion advantages

 Root penetration, corrosion performance, 90%N2 + 10%H2 for

Austenitic & duplex steels without any risk of hydrogen
 Welding Consumable Gases
welding gases
• GMAW, FCAW, TIG, Oxy- Fuel
• Supplied in cylinders or storage tanks for
large quantities
• Colour coded cylinders to minimise wrong
use
• Subject to regulations concerned
handling, quantities and positioning of
storage areas
• Moisture content is limited to avoid cold
cracking
• Dew point (the temperature at which the
vapour begins to condense) must be
checked

4/23/2007 60 of 691
EN 1089-3 which has replaced the old cylinder colour scheme BS349
EN 1089-3 which has replaced the old cylinder colour scheme BS349
BS341, DIN 477 and CGA connections
 Selecting Gas Hose For High Purity Plasma Welding
All gases, such as oxygen, moisture, carbon dioxide, and nitrogen, can
diffuse through walls of just about all hoses and plastics.
Permeation is absent only in all metal all welded pipes.
Permeation is primarily dependent upon:
1. Exposed surface area
The longer the hose or the bigger the hose OD, the greater the permeation.
2. Length of diffusion path
The longer the path to diffuse, the less the permeation. Thick walled hoses are
preferable.
3. Material of construction
Most important criteria.
HIGHEST————–——PERMEATION—————————-LOWEST
Neoprene Rubber Butyl Rubber PVC Tygon PE Polypropylene Teflon PTFE Kel-F Metal
 Selecting Gas Hose For High Purity Plasma Welding

HIGHEST————–——PERMEATION—————————-LOWEST
Neoprene Rubber Butyl Rubber PVC Tygon PE Polypropylene Teflon PTFE Kel-F Metal

4. Nature of containment
Except for Teflon and polypropylene, most plastics allow a much bigger degree of
moisture permeation than oxygen permeation.
5. Temperature & Humidity
The higher the humidity, the greater the moisture permeation.
Also, the moisture permeation rate is Higher at higher temperatures but at the
same relative humidity.
E.g. Moisture permeation at 95° F is approximately double than at 75° F
 Choose the shortest thick walled hose, made of PVC.
In moisture sensitive applications, suggest replacing hoses with PP or PE (
high density) tubing.

Stainless steel tubing can be used to insure no contamination enters the

gas lines.
The stainless steel tubing must be clean prior to install! For the highest purity
use stainless steel tubing with Ultra high purity gas, and a gas purification system.
 Gas Purity and Mixture Accuracy
Purity classification is expressed as a quality code (e.g. 5.5),

where the number before the point represents the number of nines
and the last number indicates the last decimal
5.5 = 99.9995%
6.0 = 99.9999%

The given percentage value represents the defined minimum purity of

actual gas.

In the case of liquefied gas, the purity always represents the

vaporized liquid phase.

Standard mixtures are delivered in molar units.

• R&D mixtures are specified by the customer and can be based on volume,
weight or molar units or other concentration bases such as, μ-gram/litre or mg/m3 on
request.
  Blending tolerance is the maximum difference between the ordered
concentration and the delivered mixture.
 The blending tolerance varies depending on preparation method and is
normally given as percentage relative to the component.
 A blending tolerance of 10% for a gas mixture with the concentration
250 ppm means that the mixture will contain 250 ppm ±10% of the component.
 This means a true concentration between 225 ppm and 275 ppm.
Example:
Blending tolerance: ±10% relative Analysis uncertainty: ±2% relative
250 ppm He balance N2
 Thank You
for
Your Attention

Please Do not hesitate to Question

Asst.Prof. Manoon Lertvijitpun

Tel. 66-081 828 1564 Email: manoonlp@gmail.com
Manoonlp / IP / WdET / CIT / KMUTNB 12 / October. / 2555 73