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Gases: For
Now And
The Future
Penetration
Contamination Tolerance
Melt Off Rate
Mechanical Properties
Welding Speed
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
Gas Purity
Argon-Carbon Dioxide
Ar-8% CO2
Ar-10/15% CO2
Ar-20/25%
CO2
100%
CO2
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
Ar-20/25%
CO2
Both In
and Out-of-Position
Good Performance with Most All-Position
Flux-Cored Wires
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
JOB REQUIREMENT
active gases.
Penetration profile
COMPARE GASES BY
EXAMINING :
Metal Transfer
Spatter Generated
Level of Welding Fume
Bead Shape
Penetration
Weld Mechanical Properties
Obtainable Welding Speeds
I. ShortMELT RATE
Circuiting
DROP
ARC
BEFORE
TRANSFER
FEED
RATE
NO ARC
NEW
ARC
DURING SHORT
CIRCUIT
AFTER TRANSFER
II.
Globula
r
Globular
Transfer
Arc instability,
Higher spatter level,
Broader penetration.
III.
Spray
Spray
Transfer
IV.
Pulsed
Spray
No Wire
Necking
Droplet Transfers
With Pulse
Pulsed Spray
Transfer
(a)
(a)
(b)
(a)
(b)
(b)
(a)
(b)
spray transfer,
Spatter free process,
Allows spray arc on thin materials,
May be used in all welding positions.
(b)
(a)
Apk
Abk
TIME
Globular transfer
Spray transfer
Pulsed transfer
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
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
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