Shielding

Gases: For
Now And
The Future

Making Our Planet

More Productive
SG0
1

 WHY USE A SHIELDING GAS?

To Protect the Molten
Metal as it is Transferred
from the Arc to the Weld
Zone
To
provide a Arc Plasma
To Promote a Stable Arc
To Provide Oxygen for
Wetting
To Control the Mode of
Metal Transfer
To control Weld Cost

Functions & Influence of Shielding Gas

Shielding gases protects the weld
pool, molten wire and the electric arc
from air contamination (N2, O2 and
water vapor).
Shielding gases play a major role in
the GMAW and other processes by
influencing:
Metal Transfer
Spatter level
Bead Appearance
Bead Profile
Fume Formation

Penetration
Contamination Tolerance
Melt Off Rate
Mechanical Properties
Welding Speed

BASIC GAS PROPERTIES

Ionization Potential
Electromagnetic Pinch
Force
Thermal Conductivity
Dissociation/Recom
bination
Reactivity
Surface Tension

Gas Purity
Gas Density

 ARGON
Why Is It Used?
Inert
Good alloy retention
Good mechanical properties
Low ionization potential
Good arc stability
Easy arc starting
Promotes spray transfer
Low spatter with clean welds
High productivity

CARBON DI-OXIDE
Why Is It Used?
Low cost (???)
High ionization potential
Globular metal transfer
Higher spatter levels
Dissociation / Recombination
More heat into base material
Broader penetration

BASIC GAS PROPERTIES

Gas Purity

WHY DO WE NEED GAS

BLENDS?
To Meet the Need for Better Weld Quality and
Mechanical Properties at High Levels of Productivity

To Enhance Productivity by Tailoring a Gas Blend to a

Specific Application

To Meet the Need for Improved Performance

Pulsed MIG: Stainless and Alloy Steels
High Strength Steel Welding
High Productivity Welding Processes
(High Deposition)

SPRAY AND PULSED SPRAY

MIG (GMAW) SHIELDING
GASES

Argon-Carbon Dioxide

Carbon dioxide added in smaller amounts (5-25%) to

increase arc stability, improve bead shape and wetting
action, and broaden penetration
Ar-5% CO2

Ar-8% CO2
Ar-10/15% CO2
Ar-20/25%
CO2
100%
CO2

SPRAY AND PULSED SPRAY

MIG (GMAW) SHIELDING
GASES
Ar-10/15% CO
2

Excellent Multi-Purpose
Blend for Solid, Metal-Cored,
and Specially Formulated
Flux-Cored Wires
Very Good Arc Stability and
Weld Puddle Control; Higher
Weld Travel Speeds Possible
Increased Penetration in
Heavier Materials

 SPRAY, SEMI SPRAY & SHORT-CIRUITING

TRANSFER MIG (GMAW) SHIELDING GASES

Ar-20/25%
CO2

Optimum Short Circuiting Transfer Blend

Good Arc Stability and Bead Appearance

Both In
and Out-of-Position
Good Performance with Most All-Position

Flux-Cored Wires

 SPRAY, SEMI SPRAY & SHORT-CIRUITING TRANSFER

MIG (GMAW) SHIELDING GASES

CO2
More Heat into Base Material for Greater
Penetration
More Difficult to Use Out-of-Position
Higher Spatter Levels
Due to Less-Controllable
Globular Metal Transfer
Generally Used for
Carbon Steel Only with
Solid, Large Diameter
and Specially
Designed All-Position
Flux-Cored Wires

Selecting a Shielding Gas MIG/MAG

Fume level

JOB REQUIREMENT

Select gases with less

active gases.

Penetration profile

Argon + CO2 or Helium

mixtures provide broader

penetration,
Lower amount of active
gas is required than
regular spray.

COMPARE GASES BY
EXAMINING :

Metal Transfer

Spatter Generated
Level of Welding Fume
Bead Shape
Penetration
Weld Mechanical Properties
Obtainable Welding Speeds

 TYPES OF METAL TRANSFER

I. ShortMELT RATE
Circuiting

DROP
ARC

BEFORE
TRANSFER

FEED
RATE

NO ARC

NEW
ARC

DURING SHORT
CIRCUIT

AFTER TRANSFER

Types of Metal Transfer : Short

Circuit

A gas metal arc welding process variation in which

the consumable is deposited during repeated short
circuits.

Low heat input, good for thin sheet

and when less distortion is required,

All position process,
Good weld puddle control.

TYPES OF METAL TRANSFER

II.
Globula
r

Globular
Transfer

Types of Metal Transfer : Globular

A gas metal arc welding process variation
characterized by the transfer of molten
metal in large droplets across or beside the
arc.

Arc instability,
Higher spatter level,
Broader penetration.

TYPES OF METAL TRANSFER

III.
Spray

Spray
Transfer

Types of Metal Transfer : Spray

A gas metal arc welding process variation
characterized by the transfer of molten metal
in small droplets that are propelled across the
arc.

High speed and high deposition welds,

Low spatter level and clean welds,
Limited to in position welds.

TYPES OF METAL TRANSFER

IV.
Pulsed
Spray
No Wire
Necking

Droplet Transfers
With Pulse

Pulsed Spray
Transfer

Types of Metal Transfer : Pulsed

A
process variation characterized by the transfer
of droplets during current peaks (b), above transition
current, that surpass a background current (a).
Amp

(a)
(a)

(b)

(a)

(b)

(b)
(a)

(b)

Requires a shielding gas that support

spray transfer,
Spatter free process,
Allows spray arc on thin materials,
May be used in all welding positions.

(b)
(a)

Apk

Abk
TIME

Types of Metal Transfer :

Short transfer (all gases)

Globular transfer (Carbon dioxide)

Spray transfer (argon blends)

Pulsed transfer (argon blends plus

special equipment)

TYPE OF METAL TRANSFER

Short circuit

Select argon + 15 to 25% CO2 for carbon steel

Globular transfer

Typical with CO2,

Try to avoid it while welding carbon steel in medium

to high energy (spatter).

Spray transfer

Select gases with low ionization potential. They are

normally rich in argon or contain oxygen.

Pulsed transfer

Select gases with low ionization potential which are

normally rich in argon,

Lower amount of active gas is required than regular
spray.

SUMMARY
Metal Transfer
Argon-Based Mixtures
Provide Spray Transfer For Low Spatter and High Deposition
Rates
Controlled Short-Circuiting Transfer Provides Low Heat Input for
Minimum Distortion and Out-of-Position Welding Capability

Carbon Dioxide
Globular and Short-Circuiting Transfer Only
Suitable for use with Carbon Steels
Limited Out-of-Position Capability

WELD METAL
SPATTER
Argon -Based Mixes
Low Spatter Levels
High Deposition Efficiency
Low Equipment Maintenance Costs

Carbon Dioxide
Higher Spatter Levels
Lower Deposition Efficiency (Higher Wire Costs)
Additional Parts Cleaning Required for Best Appearance

Higher Level of Equipment Maintenance

FUME GENERATION RATE

(Mg/Min.)

PROCESS COMPARISION FUME GENERATION RATES

2800

E7024
SMAW

2400

E7018
SMAW

2000
1600
1200

E71T-1
(C-25)
FCAW
ER70S-3
(CO2)
GMAW
ER70S-3
(Ar-MIX)
SPRAY GMAW

800
400
0
0

E70T-4
SELF-SHIELDED
FCAW

ER70T-1
(CO2)
GMAW
ER70S-3
(Ar-O2, -Ar-CO2)
HIGH DENSITY
SPRAY GMAW

6
8 10 12 14 16 18 20
DEPOSITION RATE (Lb./Hr.)

22

HOW CAN WELDING

FUME EXPOSURE BE
REDUCED?
Choose Welding
Process Meeting Job Requirements
with Lowest Fume Generation Rates
Optimize Selection of Welding Materials
Low Fume Wires
Argon-Based Shielding Gases

Reposition Work to Keep Welder's Head Out of Fume Plume

Provide Improved Ventilation, Exhaust at the Arc

WELD BEAD
SHAPE
Argon-Based
Mixes
Flatter Weld Bead
Less Unnecessary Reinforcement
More Efficient Use of Weld Metal

Carbon Dioxide
Crowned Weld Bead
Greater Reinforcement
Less Efficient Use of Weld Metal
Higher Weld Costs

PENETRAT
ION Mixes
Argon-Based

Controlled Penetration
Less Burn-Through
More Tolerant to Mismatch
Same Depth of Penetration as CO2

Carbon Dioxide
Hotter Arc, More Difficult to Control
Penetration
Greater Burn-Through and Distortion
Broader Bead Penetration Profile

WELD MECHANICAL
PROPERTIES
Argon+CO2 Mixture versus
Carbon Dioxide
GMAW Multipass Welds
Mechanical Properties
Summary
WIRE TYPE
SHIELDING
TENSILE
YIELD
GAS

STRENGTH
(ksi)
71.4
58.3

TOUGHNESS
@-20F (ft-lbs)

ER7OS-2

STARGON
CO2

STRENGTH
(ksi)
81.7
71.8

ER7OS-3

STARGON
CO2

77.0
74.5

63.0
60.0

84
66

ER7OS-7

STARGON
CO2

83.8
79.7

69.0
64.2

49
30

ER7OS-6

STARGON
CO2

87.2
84.9

72.5
69.0

59
37

65
20

MECHANICAL
PROPERTIES
Argon-Based Mixes
Good Alloy Recovery
Low Residual Gas Content in Weld
Greater Tensile and Impact Strength

Carbon Dioxide
More Oxidizing, Less Alloy Recovery
Lower Tensile Strength and Generally Lower Toughness

WELDING
SPEED
Argon-Based Mixes
Drastically Higher Speeds on Heavier Materials (1/4" +)
Competitive Travel Speeds in Most Applications

SUMMA
RY Welding Processes Trend
Converting CO2 to Argon Blends
Significant changes
Welding speed
Spatter level
Fume levels
Deposition efficiency
( less over weld )
Cleaning time (labor)

CO2

Trend in USA
70%
60%
50%
40%
30%
20%
10%
0%

CO2

ARGON BLENDS

Argon blend