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CWA-Toronto 4th Nov 2003

Choice of Shielding Gases

Applications of Shielding Gases
& Modes of Metal Transfer

Viwek Vaidya

Too many choices!

Too many base metals

Too many processes
Too many brands
Variety of opinions!
Gas compositions
often unknown
A5.32 - shielding gas
standard

Shielding gas components

CO2 - Dirty gas needs cleaning

Argon From cryogenic processing
Oxygen - From cryogenic processing
Helium From mines of Natural gas
Hydrogen Chemical processing
Nitrogen From cryogenic processing

The functions of shielding gases are

Protect the weld pool from atmosphere
Provide a gas plasma - ionised gas
Support metal transfer and bead wetting

Physical properties of pure gases

Size and shape of the plasma column depends on:
thermal conductivity

specific gravity:
determines the heat content of the gas

Ionization potential:
ease of carrying electrical energy

High thermal conductivity gases

CO2 and He have high thermal conductivities
For equal energy into the plasma
less surface needed to transmit heat
Plasma column remains narrow
Localised under the molten tip of wire

This produces globular transfer

Globular transfer
High thermal
conductivity
Narrow plasma
column
CO2 and Helium
produce globular
transfer
Impossible to produce
spray transfer!

Thermal conductivity and plasma shape

Thermal Conductivity is the ease with which the
gas will dissipate heat
Argon has low thermal conductivity
It is used for low R-Value windows

Argon

Low thermal conductivity gases

Argon has low thermal conductivity
For equal energy into the plasma
more surface is needed to transmit heat
Plasma column expands
Reaches beyond the molten tip of wire
Rapid melting with high electron condensation
heating

This produces spray transfer

Spray Transfer
Low thermal
conductivity
Expanded plasma
column
Electron condensation
heating

Spray Transfer
Wire melts in a fast
fine droplet stream
Wire end becomes
pointed
Spray transfer results
in high deposition and
good penetration
Argon gives spray
transfer!

Penetration profiles
Argon has a finger nail
penetration profile
consistent with spray
transfer
CO2 and He have
elliptical penetration
consistent with the
globular transfer

The 90/10 rule

To ensure a smooth spray transfer
remember this rule!
90% Innert gas (Ar/He)
10% Active gas (Active gas component)
These could be CO2/O2 combinations
For welding steel or stainless base
materials some oxygen or CO2 is needed
for arc stability

Spray transfer limits

Below 85% Argon content, spray transfer
is not possible
Beyond 5% Oxygen levels, fume
emissions become a problem
Although He is innert, it promotes
globular transfer
Any gas mixture that will spray transfer,
will generally pulse and short circuit
Hydrogen will provide heat and clean
oxides

Shielding gas choice

Quiz time!

Argon Helium mix

75%Ar+25% He
Applicable to what base metals?

Argon Helium mix

50%Ar+50% He
What is the bead shape?
What is the advantage with respect to Blue
Shield 1?

Argon Helium mix*

25%Ar+75% He
*Can one spray transfer with this gas?
Why?
What application ? Automatic or manual?

Argon Oxygen mix

98%Ar+2%O2
This gas can be applied to what base
metals?
What would be the bead shape?

Argon Oxygen mix*

95%Ar+5% O2
Can one spray transfer with this gas?
*Can this be applied to Stainless steels?

Argon CO2 mix*

90%Ar+10%CO2
Bench mark composition for spray transfer.
*What would be the weld bead shape
compared to Ar-5%O2

Argon CO2 *
85%Ar+15% CO2
Can this gas be used for GMAW spray
transfer?
*Can this gas be used for FCAW mild steel,
and stainless steel?

Argon CO2 *
75%Ar+25% CO2
Can one spray transfer with this gas?
How will the bead shape look compared to
CO2
*What will the fillet weld penetration be
like compared to CO2? What about fumes?

Helium Argon CO2 mix*

90%He+7.5%Ar+2.5% CO2
*Can one spray transfer with this mixture?
Why?
What base metal should be welded with this
mix?

Argon H2 mix *
97.5%Ar+2.5% H2
*Can this gas be used for GTAW of ferrous
metals?

Argon H2 mix *
65%Ar+35% H2
*Is this a welding grade gas? Where is this
applied?

Nitrogen H2 mix *
95%N 2+5% H2
*Can you weld with this gas? In what
application?

Argon CO2 O2 mix*

91%Ar+5% CO2 +4% O2
Can one short circuit and spray with this gas?
* How will it weld on non blasted plate, GMAW?
Why?

Argon Helium CO2 mix*

81%Ar+18%He+1% CO2
Where would this gas composition be used?
Magnesium, copper, mild steels or SS?
*Can one short circuit and spray transfer
with this mix? Why?

Argon CO2 Helium mix*

75%Ar + 15% CO2 + 10%He
*What advantage would this gas have over
a 85% Argon + 15% CO2?

Thank you for your attention!

Questions?