In the gas shielded welding process, while gas is one of the key parameters, its importance is often overlooked. Traditionally, many believe that lower procurement costs for consumables directly translate to better economic outcomes. However, with technological advancements, modern welding focuses on using innovative techniques to boost productivity and reduce overall costs. Protective gas, though accounting for only about 5% of total welding costs, plays a critical role in determining the quality and efficiency of the weld.
Common shielding gases used in welding include argon (Ar), carbon dioxide (COâ‚‚), and sometimes oxygen (Oâ‚‚), hydrogen (Hâ‚‚), helium (He), or nitrogen (Nâ‚‚), depending on the application. These gases have unique physical properties that influence their behavior during the welding process. The development of shielding gases has been driven by the need to optimize these properties for different welding scenarios.
From a technical perspective, adjusting the composition of the shielding gas can significantly impact the welding process in several ways:
1. **Increased Wire Deposition Rate**: Argon-rich mixtures typically offer higher production efficiency compared to pure COâ‚‚. To achieve jet transfer, the argon content should be above 85%. Proper selection of welding parameters is essential to maximize efficiency and minimize post-weld cleanup.
2. **Reduced Spatter and Improved Arc Stability**: By reducing the ionization potential of the slag, spatter can be minimized, leading to a more stable arc. New power technologies have further reduced spatter in COâ‚‚ welding, and gas mixtures can enhance this effect.
3. **Controlled Weld Formation**: COâ‚‚ tends to produce convex welds, which may lead to excessive metal deposition. Mixing with argon helps control the shape of the weld and reduces wasted wire.
4. **Higher Welding Speed**: Argon-rich gases allow for faster welding speeds without increasing spatter, especially beneficial in automated systems where speed is crucial.
5. **Lower Fume Emissions**: Argon-based mixtures significantly reduce welding fumes compared to COâ‚‚, offering environmental benefits without the need for costly hardware upgrades.
In summary, choosing the right shielding gas not only improves weld quality but also lowers overall costs and increases efficiency. While argon mixtures are widely used, particularly in industries like automotive manufacturing, many companies still rely on standard mixes like 80% Ar + 20% CO₂, which may not always yield optimal results. Selecting the best gas requires understanding specific welding needs, as well as maintaining the correct gas flow rate—too high or too low can negatively affect the weld.
**Typical Products**
1. **Stargold Binary Argon Mixture**: This gas offers a stable arc, clean weld surface, and minimal spatter, eliminating the need for post-weld polishing. In some auto parts applications, it reduces oxide scale, improving paint adhesion. As shown in Figure 1, Stargold 5 produces smooth, clean welds without splashing.
2. **Robostar Ternary Gas Mixture**: Ideal for automatic welding, Robostar enhances penetration and welding speed. It supports various droplet transfer modes and improves joint fatigue strength, making it ideal for the automotive industry. It helps avoid stress concentrations at the weld-to-base metal interface, as seen in Figure 2.
3. **Stargon**: Compared to CO₂, Stargon increases welding speed by 20–30% and reduces fumes by 50–100%, making it an eco-friendly option. It ensures a stable process and high-quality welds, as illustrated in Figure 3.
For materials like stainless steel and aluminum alloys, specific gas mixtures are recommended based on material thickness. Table 2 outlines some of Praxair’s suggested protective gases for different base metals.
Looking ahead, as new welding processes and materials emerge, shielding gases will continue to evolve. The focus will be on increasing welding speed, improving efficiency, and reducing fumes. However, even the best gas must be paired with appropriate welding parameters to achieve optimal results. Modern gas suppliers now act as comprehensive solution providers, integrating gas knowledge with broader welding technology.
The China Welding Technology Center, one of Praxair’s top labs, has dedicated over a decade to researching and applying these innovations at the production level.
In 2014, improving management efficiency, product quality, and process performance became essential for all welding enterprises. A small change in shielding gas can have a significant impact on the entire welding operation. Understanding how to use gas effectively is a critical consideration for every company. Collaborating with advanced gas producers and optimizing welding parameters will be the key to achieving efficient, high-quality production.
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