Ionization: is the process of converting an atom or
molecule into an ion by adding or removing charged particles such as electrons or ions.
Ionization potential: is the energy required to remove electrons from gaseous atoms or ions.
Shielding gases for welding: Protects the molten metal or arc area from the atmosphere. It also influences the metal transfer mode and deposited weld characteristics. Shielding efficiency- depends on design of nozzle, gas flow rate, side winds, purity of shielding gas etc. Shielding gases
Active (O 2, Co 2 , H 2 etc) Inert (Ar, He, Ne, Kr etc) Used with GTAW and for welding non-ferrous metals with GMAW Properties of shielding gas: 1. Ionization potential (IP): Ionization potential 1
- Argon has low IP and helps to initiate and maintain the arc in a stable operating mode. - Helium has high IP
2. Thermal conductivity: - Pure Ar has low thermal conductivity. Hence weld fusion area has wider top and a narrow finger at the root. - Helium has higher thermal conductivity. Therefore results in broader, hotter arc. Molecular weight of shielding gas Argon Carbon Dioxide
Heium Hydrogen
Nitroge n
oxygen
Chemical symbol Ar Co 2 He H 2 N 2 O 2 Atomic Number 18 6 2 1 7 8 Molecular weight 39.95 44.01 4.00 2.016 28.01 32.00 Specific Gravity, Air = 1 1.38 1.53 0.1368 0.0695 0.967 1.105 Density(lb/cu ft) at 0 C, 1 atmosphere 0.1114 0.1235 0.0111 0.0056 0.0782 0.0892 Ionization Potential(ev) 15.7 14.4 24.5 13.5 14.5 13.2 Thermal Conductivity (10 -3 Btu/hr-ft-F) 9.69 (32 F) 8.62 (32 F) 85.78 (32 F) 97.22 (32 F) 13.93 (32 F) 14.05 (32 F) Cubic ft/lb 9.67 8.73 96.71 192 13.8 12.08
3. Specific gravity: weight of gas with respect to air. - Helium is a light gas, so floats away and will not be an efficient shield. Hence gas flow rate must be increased.
4. Dissociation and recombination: Co 2 ,H 2 ,O 2 are multi atom molecules. - at higher temperatures, they disintegrate or dissociate into component atoms. - when dissociated atoms come into contact at the relatively cool work surface , they recombine and release heat at that point.
5.Reactivity: - Ar, He completely non reactive - Co 2 ,O 2 reactive gases react with FM or base plate enhance stability of the arc and affect the type of metal transfer
6. Surface tension: influences bead shape - if high, convex & irregular bead will result - low values promote flatter beads with minimal susceptibility to undercutting. - Pure Ar produces sluggish weld puddle and high crowned bead - if O 2 added to Ar, lowers surface tension and promotes fluidity and better wetting of base material.
7. Gas Purity: - gas impurities affect welding speed, weld surface appearance, porosity level etc.
Argon: Colorless, odorless, tasteless and non-toxic, 1.4 times heavier than air- promotes good arc starting characteristics and arc stability due to low IP. - The arc voltage of the tungsten arc in argon is lower than in helium.
Helium: lighter than air. Has high thermal conductivity and high IP-hence used when increased heat input is desired and also for Al, Mg welding. Helium light weight causes it to float away from the arc zone, producing an inefficient shielding. Helium is expansive for welding and is sometimes in scarce supply.
Co 2 : is a compound of about 27% carbon and 72% oxygen. - reactive gas, 1.5 times heavier than air. Odorless, colorless with a slightly pungent acid taste. - Co 2 can be used alone for GMAW shielding gas applications -Co 2 + Ar is used to improve productivity and penetration in GMAW. - oxidising gas so use GMAW wires with high contents of Si & Mn. - 100% Co 2 shielding produces broad, deep penetration welds. - inexpensive compared to inert gas - drawback: arc can be somewhat violent- leads to spatter and makes welding of thin materials difficult- so go for Ar- Co 2 mixtures
H 2 : lightest element known, has high thermal conductivity and reactive nature.
GMAW & GTAW of 300 series of stainless steel use H 2 .
N 2 : colorless, odorless, tasteless, slightly lighter than air.
N 2 is inert except at welding temperature when it reacts with Al, Mg and Ti.
Not recommended for 1 shielding gas with GMAW but used as assist gas in laser cutting on Stainless steel.
O 2 : Highly oxidizing & vigorously supports combustion Oxygen normally added in amounts of 1% to 2%, or 3% to 5%.This provides for spry transfer. O 2 added with Ar for GMAW to increase arc stability and to improve the shape of weld bead. also used to increase cutting speeds with plasma and laser processes More oxygen will leads to porosity. Different gas mixtures -2 gases duplex mixtures and 3 gases Ternary Mixtures of gases -Mixtures combine inert + active gases - for GTAW--- inert gases normally used Argon + O 2 : for GTAW, O 2 < 1% used to help stiffen the arc - used for thin steels, S.S, DCEN of Al. -In GMAW, it decides metal transfer mode. - Pure Argon produces poor bead contour and penetration pattern.This is eliminated by adding O 2 , 1% to 2%, 3-5%O 2 (spray transfer) --the more oxidizing the shielding gas use electrode with sufficient deoxidizers to overcome loss of Mn, Si, Al. Advantage: good penetration pattern by broadening the deep penetration finger, eliminates undercut due to better wetting action. Disadvantage: more O 2 leads to porosity
Shielding gas related to weld profile for DCEP Ar +He: - Ar +He used for welding non-ferrous metal with GMAW. - 50 to 75% of He increases arc voltage and heat in the arc. -So used in welding heavy thickness of Al, Mg, and Cu and for overhead position welding.
Ar + H 2 : - Ar + small amounts of H 2 increases heat in the arc . -Ar +5%H 2 : Ni &Ni alloys also for welding heavier sections of austenitic stainless steel. - Ar + 25%H 2 : welding thick metals that have high thermal conductivity like Cu. -cannot be used to weld mild or low alloy steels due to the problem of H 2 pickup - H 2 should not be used with Al and Mg. Ar+N 2 : -In some countries pure N 2 used for GMAW of Cu- quality of weld is not good as desired. -adding 50-75% Ar to N 2 produce higher quality weld
Ar+Co 2 : -75% Ar +25%Co 2 used in GMAW -widely used on thin steel where deep penetration is not necessary and where bead appearance is important. -spatter is reduced. - it is also helpful for out-of-position welding. Ternary mixtures of gases: - three-component mixtures : Ar + O 2 +Co 2 and sometimes Ar + Co 2 +He. 70%Ar + 2% O 2 + Co 2 used for welding steels. - small amount of He to Ar-O 2 mixture increases arc voltage and provides higher deposition rates or higher travel speeds. Flux A substance that prevents formation of oxides and other contaminants in welding, or dissolves them and facilitates removal Provides protective atmosphere for welding Stabilizes arc Reduces spattering Flux Application Pouring granular flux onto welding operation Stick electrode coated with flux material that melts during welding to cover operation Tubular electrodes in which flux is contained in the core and released as electrode is consumed Electrode coatings Electrode coatings can consist of a number of different compounds, including Rutile , calcium fluoride, cellulose, and iron powder. Rutile electrodes, coated with 25%45% TiO 2 , are characterized by ease of use and good appearance of the resulting weld. Helps to form a highly fluid but quick freezing slag. Also provides ionisation for the arc. However, they create welds with high hydrogen content, encouraging embrittlement and cracking.
Electrodes containing calcium fluoride (CaF 2 ), sometimes known as basic or low-hydrogen electrodes, are hygroscopic and must be stored in dry conditions. They produce strong welds, but with a coarse and convex-shaped joint surface. Electrodes coated with cellulose, especially when combined with rutile, provide deep weld penetration, but because of their high moisture content, special procedures must be used to prevent excessive risk of cracking.
Iron powder is a common coating additive, as it improves the productivity of the electrode by increasing deposition rate, sometimes as much as doubling the yield.
Metal Carbonates: adjusts the basicity of the slag & provides a reducing atoms. Coating Materials -Partial List Arc Stabilizers Titania TiO 2