Beruflich Dokumente
Kultur Dokumente
January 9, 2007
Depending on your application, various components of your shielding gas blend can help or hurt
you. Find out what effects shielding gas has on your weld and what you can do to get the best
results.
Although you probably know that shielding gas is essential in most welding procedure
specifications, you may pay little attention when you're selecting it. A simple gas composition
change can offer potential savings in seven key areas, particularly in gas metal arc welding
(GMAW).
Shielding gas typically isn't considered to have much of an effect on the cost of a welding
operation. Many welders don't fully understand the financial impact that shielding gas can have
on the bottom-line cost of the welding operation.
Which shielding gas composition you choose for GMAW can affect your welding operation in
seven key ways.
Although helium costs more than argon, shielding gas typically comprises less than 5 percent of
the total welding cost, making the addition of helium something to consider when choosing a
shielding gas blend.
Electrode deposition efficiency is linked directly to the welding spatter level. High-argon blends
typically produce the best results in spray transfer. Improved deposition efficiency also can be a
function of choosing the right welding parameters. A nonoptimized system—in which any
number of parameters, such as gas flow rate and voltage, aren't optimized—generally produces
lower deposition efficiency and may contribute to increased postweld cleanup costs.
If you use spray arc transfer, generally the argon level should be 85 percent or more. Pulsed
spray transfer with a 95 percent argon blend typically will yield the lowest spatter levels when
welding plain carbon steel. A three-part blend of argon, helium, and carbon dioxide can reduce
weld spatter when joining galvanized steel or steel with some residual surface oil or scale.
In general, GMAW is a slag-free process, but slag islands still are common on the bead surface.
Powder and paint won't adhere to these silicon deposits. Low shielding gas reactivity can help to
reduce these surface residuals. If you're concerned about slag island buildup along the edge of
the weld bead, work only with properly cleaned base material and use a blend containing at least
90 percent argon with no oxygen. Choosing filler metal carefully also will help limit island
formations.
Postweld cleanup can increase cost, reduce your arc-on time, and decrease the welding
operation's duty cycle. Because it reduces spatter, an optimal argon blend may help you reduce
postweld grinding, which means you can dedicate more time to welding.
Color match typically is a concern when welding stainless steels. For the best color match, select
a blend of argon or helium with low levels of oxygen or CO2 to minimize weld surface
oxidation. Oxygen-free blends produce less weld metal discoloration. To further minimize
discoloration, use a low operating current and a large gas nozzle with close nozzle-to-work
distance to ensure good shielding gas coverage. When joining 300 series stainless steel, you can
add a controlled amount of hydrogen—less than 5 percent—to lessen oxidation and therefore
improve bead color and enhance productivity. If corrosion resistance is important, limit CO2
content to less than 5 percent.
Filler metal diameter also plays a critical role in optimizing bead shape. A large wire size can
make it difficult to control the weld bead size. An oversized weld bead can increase welding
costs by at least 50 percent. Choose your filler metal type and size based on the needs of your
application.
Pure CO2 can help you achieve good weld penetration. The operating current, filler metal, and
gas composition also affect the penetration profile. If you want deep penetration, use an argon
blend with a high percentage of CO2—15 percent to 20 percent—or perhaps consider adding
helium to broaden and deepen penetration. This also will contribute to better welding
productivity.
5. Out-of-position Weldability
Shielding gases with greater reactivity, which use more CO2 or O2, will increase weld pool
fluidity. For out-of-position work, this may force you to use slower wire feed rates, which will
decrease productivity.
The type of metal transfer you choose also is critical when trying to improve out-of-position
control. High-argon blends with low reactivity generally perform well.
The shielding gas you choose can affect many welding characteristics. Once you understand
which properties are most important for your application, you can select the best blend for the
job.