Introduction Gas Shielded Arc Welding
Introduction Gas Shielded Arc Welding
CONTENTS
1. INTRODUCTION................................................................................................................. 3
1. INTRODUCTION
ª Argon,
ª Helium,
ª Hydrogen,
ª Carbon dioxide,
ª Oxygen,
ª Nitrogen (backing).
They are used pure or in a mixture to improve the
productivity of the process and/or the quality of the
weld bead. If gas shielding is poor, the following
types of flaw appear:
2. WELDING EQUIPMENT
The gas-shielded metal arc welding set must include the following components:
1. A current generator,
2. A control unit,
3. A filler metal feed system,
4. A welding gas supply,
5. A cooling device,
6. A torch or gun,
7. A welding harness.
Diagram of a MIG - MAG welding set
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3. FILLER METALS
The wires used in gas-shielded metal arc welding can produce either homogeneous or heterogeneous
welds (e.g. steel + steel or steel + stainless steel).
In the case of homogeneous welding, the composition of the wire is quite close to that of the parent
metals in order to obtain similar mechanical or metallurgical characteristics to those of the joined metals.
For heterogeneous joints, the composition of the filler wire will be selected according to the mechanical
and metallurgical criteria to be obtained.
Two types of wire are used:
- solid wires,
- tubular wires (in this case, they correspond to a tube filled with flux).
3.1. STANDARDISATION
Standards classify filler wires according to the mechanical characteristics of the all-weld metal and its
chemical composition. It is advisable to choose a wire whose weld zone characteristics are superior or
equal to those of the parent metals.
Example of a standardised designation:
- filler wires for tungsten inert gas welding of unalloyed steels.
NF EN 1668 (A 81-325) Rod EN 1668 - W 46 3 W3Si1
EN 1668: standard number,
W: rod for tungsten inert gas welding,
46: strength and elongation (cf. table contained in the standard),
W3Si1: chemical composition of the filler wire or rod (cf. table contained in the standard).
4.1. ARGON
Chemical symbol: Ar
Source: distillation of air (there is approximately 0.94% argon in air)
Density in relation to air: 1.38
Boiling point at atmospheric pressure: -186°C
Chemical property: chemically inert.
4.1.1. Use
Welding: TIG, PLASMA, LASER
Cutting: PLASMA
Base of most gas mixtures.
Root cavities
4.1.2. Role and characteristics in welding
a ) Advantages
Low ionisation potential:
• With the TIG process, very good wetting, penetration and welding speed is obtained, striking is
easy (due to low ionisation potential with argon) and the arc is more stable.
With the MIG process on unalloyed and low-alloy steels, argon can produce an erratic arc.
A pointed form of penetration, known as wineglass penetration, can lead to:
b ) Drawbacks
• Risk of cavity formation at the base of the
bead
• It is an asphyxiating gas because, being
heavier than air, it can replace the oxygen in
the air and reduce its proportion.
4.1.3. Packaging Beware of interpenetration problems
ª Cylinders and cylinder bundles
ª Bulk: liquid in cryogenic evaporators.
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4.1.4. Safety
ª Inert.
ª Non-flammable.
ª Non-toxic.
ª Does not support life.
4.2. HELIUM
Chemical symbol: He
Source: natural gas fields where low quantities are present
Density in relation to air: 0.138
Boiling point at atmospheric pressure: -269°C
Chemical property: inert.
4.2.1. Use
Welding: TIG,MIG, PLASMA
ª Improved wetting;
ª Broader penetration at the root: Good wetting and massive root
ª Improved compactness,
ª Better interpenetration between passes,
ª Increased welding speeds.
b ) Drawbacks
Its low density requires higher flowrates.
High ionisation potential:
4.2.3. Packaging
ª Cylinders and cylinder bundles
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4.2.4. Safety
ª Inert.
ª Non-flammable.
ª Non-toxic.
ª Does not support life.
4.3. HYDROGEN
Chemical symbol: H2
Source: petrochemicals
Density in relation to air: 0.07
Boiling point at atmospheric pressure: -253°C
Chemical property: reducing
4.3.1. Use
Only mixed with argon or argon and helium.
Welding: TIG, MIG, PLASMA
Constituent of mixtures used for cutting and plasma spraying.
b ) Drawbacks
ª Risk of gas cavities in multipass welding;
ª Risk of embrittlement of unalloyed and low-alloy steels.
4.3.3. Packaging
ª Cylinders and cylinder bundles
4.3.4. Safety
ª Highly flammable.
ª Non-toxic.
ª Does not support life.
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4.4.1. Use
Welding: MAG
Used pure or mixed.
ª Improved compactness,
Broad penetration and average wetting
ª Better interpenetration between passes.
b ) Drawbacks
ª Cannot be used with spray arc transfer in a
pure state as this leads to gas cavity formation;
ª Wetting is average hence a risk of
fatigue cracking;
ª Risk of increasing the carbon content of the
weld zone on low carbon steels (limit the CO2
content in the case of stainless steels) and/or
oxidising the deposited metal.
4.4.3. Packaging
ª Cylinders and cylinder bundles. Good interpenetration
ª Bulk: liquid in refrigerated tanks.
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4.4.4. Safety
ª Non-flammable.
ª Affects vigilance (narcotic effect) and respiration (above 2%).
ª Does not support life.
4.5. OXYGEN
Chemical symbol: O2
Source: distillation of air (21% O2 in air)
Density in relation to air: 1.105
Boiling point at atmospheric pressure: -183°C
Chemical property: oxidising.
4.5.1. Use
Welding: MAG
Cutting: PLASMA
LASER
ª Improved wetting,
ª Not so good for positional welding.
Pointed form of penetration:
4.5.3. Packaging
ª Cylinders and cylinder bundles
ª Bulk: liquid in a cryogenic evaporator.
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4.5.4. Safety
ª Energetic oxidising gas
ª Oil and grease ignite spontaneously in contact with pure oxygen.
ª Beware of oxygen enrichment.
4.6. NITROGEN
Chemical symbol: N2
Source: distillation of air (78% N2 in air)
Density in relation to air: 0.968
Boiling point at atmospheric pressure: -196°C
Chemical property: non-reactive
4.6.1. Use
Forms part of the chemical composition of shielding gases for austenitic stainless steels and laser
cutting.
b ) Drawbacks
Deteriorates the mechanical properties of ferritic steels by forming metal nitrides.
4.6.3. Packaging
ª Cylinders and cylinder bundles
ª Bulk: liquid in cryogenic evaporators.
4.6.4. Safety
ª Inert, non-toxic,
ª Does not support life.
ª Risk of death by asphyxia.
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Basic constituents
Compactness
All positions
Arc stability
Penetration
Ar He H2
Wetting
Aspect
Speed
100
1 1 2 1 2 3 3
97.5 2.5
1 2 2 3 3 3 3
95 5
1 1 2 2 2 3 3
80 20
2 2 3 3 2 3 2
30 70
2 2 3 3 2 2 2
75 20 5
3 3 3 3 3 2 2
1 = Poor
2 = Good
3 = Excellent
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5.1.2.
2. Stainless steels
Compactness
Basic constituents
All positions
Arc stability
Penetration
Wetting
Aspect
Ar He H2
100 Speed
1 1 2 2 3 3 3
97.5 2.5
2 2 2 3 3 3 3
95 5
1 1 2 2 3 3 3
80 20
2 2 2 2 3 2 3
30 70
2 3 2 3 3 2 2
75 20 5
3 3 3 3 3 3 2
1 = Poor
2 = Good
3 = Excellent
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5.1.3.
.1.3. Aluminium, Copper and Titanium
Basic constituents
Compactness
All positions
Arc stability
Penetration
Ar He
Wetting
Aspect
Speed
100
1 1 3 1 2 3 3
95 5
1 1 3 2 2 3 3
80 20
2 2 3 2 3 3 3
50 50
3 3 3 3 3 2 2
30 70
3 3 2 3 3 2 2
100
3 3 2 3 3 1 1
1 = Poor
2 = Good
3 = Excellent
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5.2.
.2. GASES AND GAS MIXTURES USED IN MIG/MAG WELDING
5.2.1. Unalloyed and low-alloy steels
Basic constituents
All positions
cored wire
No spatter
spatte
Ar He CO2 O2
Wetting
Fumes
Speed
82 18
2 3 2 2 2 3 2 3
92 8
3 2 3 3 3 3 3 3
95 5
3 1 3 2 2 1 3 1
90 5 5
3 2 3 3 3 2 3 1
96 3 1
3 2 3 3 3 2 3 2
85 5 10
3 2 3 2 2 2 2 3
100
2 3 1 1 1 3 1 2
1 = Poor
2 = Good
3 = Excellent
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Basic constituents
Arc stability
No spatter
cored wire
spatte
Ar He CO2 O2 H2
Wetting
Fumes
Speed
98.5 1.5
2 2 2 3 2 2 3 2
98 2
2 2 2 3 3 3 3 2
96 3 1
2 2 2 2 2 3 2 1
81 18 1
3 3 3 3 3 2 3 2
56.5 40 2 1.5
3 3 3 3 3 1 3 2
1 = Poor
2 = Good
3 = Excellent
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5.2.3.
3. Aluminium and Copper
Basic constituents
Compactness
All positions
Arc stability
Penetration
Welding
Wetting
Ar He
speed
100
1 1 1 2 3 3
95 5
1 1 1 2 3 3
80 20
2 2 2 3 3 3
50 50
3 2 3 3 3 2
30 70
3 3 3 3 2 2
1 = Poor
2 = Good
3 = Excellent
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The classification of a gas or gas mixture is then specified on the basis of the following table.
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The designation of the aforementioned gases can therefore be obtained from this standard. The table
below indicates these standardised designations, plus the trade names used by a few gas producers:
Nertal
100 I1 Argon Carboxar 5 Argon
Argon U
95 5 I3 Arcal 31 - - -
75 20 5 R1(1) Arcal 11 - - -
85 5 10 M21(1) Eloxal 35 - - -
7. GAS STORAGE
Shielding gases can be stored in gaseous or liquid form as either pure
gas or a mixture.
When gas mixtures are prepared on site from their elementary gases,
the mixer must be designed and serviced to obtain and maintain the
mixing tolerances. It is therefore sometimes more practical to use gas
cylinders where the gases are ready mixed.
7.2. LIQUID
Liquefied gases can be supplied in one of two forms:
Low temperature (cryogenic) liquid stored in insulated tanks at atmospheric pressure (Ar, He, O2, N2);
Compressed liquid stored in gas cylinders at ambient
temperature (CO2).
Liquefied gases must regasified before use.
Storage in liquid form is advantageous when gas
consumption is particularly high insofar as it helps to
reduce the actual volume stored.
For example, 1 l of liquid argon at –186°C will produce
825 l of argon gas at ambient temperature whereas 1 l
of argon at 200 bar pressure will only produce 200 l of
gas once the pressure has been released.
Nevertheless, as a general rule, this type of storage is
restricted to pure gases.
To produce gas mixtures from liquefied gases, they
must be converted to the gaseous phase before Liquid storage
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mixing. Only argon-oxygen mixtures, gases with similar evaporating temperatures, can be stored ready
mixed in liquid form. They do not require the use of mixers for supply.
If Q1 is the flowrate reading on the calibrated flowmeter with a given gas, of density ρ1, the actual
flowrate Q of the gas or mixture, of density ρ, is given by:
The table below indicates a few correction values for various gases:
Gas used
9. CYLINDER IDENTIFICATION
Gas cylinders are colour-coded on the shoulder of the cylinder.
The colours of the cylinders refer to their contents and are used as a back-up to the cylinder labels, the
primary method for indicating cylinder contents.
The colour of the cylinder is an important method of identifying the contents when the labels cannot be
read, particularly if a cylinder cannot be approached closely enough.
At the moment, there are two identification systems:
Standard NF X 08-106, which will be phased out in 2008
Standard NF EN 1089-3 (05/97) (E 29-771-3), which will be used in parallel to the previous standard for
ten years.
Gas Colour
Nitrogen Black
Oxygen White
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Risk Colour
Flammable Red
Gas Colour
Acetylene Maroon
Oxygen White
Nitrogen Black
Helium Brown
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§1
source de chaleur Heat source
Milieu Gazeux ou Liquide ou Vide Gaseous or liquid medium or vacuum
Métal liquide Molten metal
§2
Schéma d’une installation MIG ou MAG Diagram of a MIG or MAG plant
Tube contact Contact tube
Fil électrode fusible (+) Consumable electrode wire (+)
Gâchette Trigger
Gaz de protection Shielding gas
Câble de masse (-) Ground cable (-)
Coupe d’un faisceau séparé de torche à Cross-section of a separate water-cooled torch
refroidissement par eau harness
Arrivée d’eau Water inlet
Fil électrode fusible Electrode wire
Commande gâchette Trigger control
Gaz Gas
Gaine extérieure Outer conduit
Gaine amenée fil Wire feed conduit
Câble de courant Current cable
Retour eau Water return
Coupe d’un câble coaxial… Cross-section of a coaxial water-cooled torch
cable
Conduit d’usure Wear conduit
Bobine Spool
Source de courant continu DC power source
§ 4.4.2.
Sans CO2 Without CO2
Avec CO2 With CO2
§ 7.2.
Centrale évaporateur Evaporating station
§8
Dans les formules, remplacer gaz par gas et remplacer les virgules par des points.