CO Welding: 2.1 Power Source

CO2 WELDING
1.0 Introduction:
CO2 welding is one of the variations of the GMAW ( Gas Metal
Arc Welding ) process which is now used for welding most structural
and alloy steels. The operating principle and the equipment required
are same as for GMAW. The CO2 welding system is basically very
simple. A filler wire is continuously fed by a motor driven rolls to a
welding gun where current is fed into it from a power source. The
welding arc is struck between the work piece and the tip of the wire,
which melts into the weld pool. The arc and weld pool are both
shielded be C02 gas flowing from the gun. The process is very
versatile in that, by selection of the proper wire diameter and
composition it can be used for welding of thin sheet as well as thick
plates.
2.0 Equipment:
The CO2 welding unit consists of a power source, a wire feed
unit, a torch assembly and control system.
2.1 Power source :
Normally a power source with constant potential characteristics
is used for C02 welding as it has the ability to self regulate the welding
arc. The positive polarity of the power source is always connected to
the consumable wire electrode and the negative polarity is connected
to the work piece. Transformer-Rectifier (T-R sets) type which were in
use earlier is now being fast replaced by more advanced inverter
power sources. The Transformer-Rectifier sets used to contain a
variable inductance in series to limit the rate of raise of the short
circuit current and thereby reduce the spatter loss. However, the
advent of the thyristor and transistor power sources has obviated the
need for inductance control, the rate of rise of current is now
controlled electronically. The welding voltage in these modern power
sources can be adjusted both from the panel as well as from are
mote pendent.
2.2 Wire Feeding Unit :

The wire electrodes are supplied as continues coils in wire
spools. The solid wires are available in the following sizes 0.8, 1.0,
1.2, 1.6,2.0 and 2.4 mm diameters. The wires normally would have
an uniform and thin copper coating to facilitate easy current pickup.
The copper coating also serves as good lubricant for the passage of
the wire through the torch assembly. The consumable wire electrode
is fed into the arc zone by means of the wire feed unit. The wire feed
unit consists of a wire reel holder where the wire reel is mounted and
a set of two or four rollers driven by a motor gearbox assembly. The
rollers draw out the wire from the wire reel and feed it smoothly into
the torch assembly. The wire feed rate can be varied using the control
knob. The roller pressure on the wire is to be suitably adjusted. The
wire feed unit also contains a solenoid valve, which regulates the flow
of shielding gas into the torch assembly.
2.3 C02 Gas Supply :
The C02 shielding gas is supplied in cylinders at high pressure
(140 kg/cm2). Therefore a pressure regulator and flow meter are
connected
to reduce the pressure to required level (2kg/cm 2) and
to control the flow rate of the shielding gas from the cylinder. A gas
hose connects the flow meter to the solenoid valve. The solenoid
valve, when actuated releases the shielding gas into the torch
assembly.
2.4 C02 Welding gun/Torch :
The torch assembly consists of conduits to supply the
consumable wire electrode and the shielding gas into the welding
gun. The torch assembly may also carry hoses for water circulation in
the welding gun to effectively cool it form the heat of the welding arc.
The torch assembly also contains a power cable and control cable.
The torch assembly is normally
3 to 4.5 meters long and is quite
flexible. The shielding gas flows through the annular space between
a contact tube and outer nozzle. The outer nozzle prevents air
aspiration into the arc zone. The contact tube at the center of the
welding gun guides the consumable wire electrode into the job. It also
picks up the current from the positive power cable and passes it on
the wire electrode. The welding gun is provided with a switch, which
when actuated by the welder allows the flow the welding current, the
consumable wire electrode and the shielding gas.
4. Metal Transfer in CO2 welding.

In C02 welding two distinct types of metal transfers are identified
viz. short circuiting transfer and free flight globular transfer.
4.1 Short Circuit Transfer :
When the welding voltage and the current are low, the mode of
metal transfer would be of short circuiting type. In short circuiting
mode, metal transfer occurs from tip of the wire electrode to the job
whenever the wire tip touches the weld pool. The arc is extinguished
during the short circuit period and is re-ignited after the short circuit is
cleared. Short circuiting transfer is used for joining thin sheets,
welding out of position and root pass welding of tubes and pipes.
4.2 Free Flight Transfer :
When the are voltage and current are high, the metal droplets
are transferred non axially as large globules and this is called non
axial free flight transfer. The non axial free flight transfer produces
deep penetration. Hence this mode of transfer is used for welding
thick sections in down hand and horizontal positions.
5. Electrode wire for CO2 welding:

CO2 welding wire must have a special composition to withstand
the oxidising nature of the C0 2 arc atmosphere. Though C02 is not
reactive at room temperature, but at the high temperature of the arc it
is dissociated into carbon monoxide and atomic oxygen.
CO2 = CO + O
Under these oxidising conditions, the carbon present in an
unkilled weld pool would react with the oxygen and form carbon
monoxide, and thus form porosity. To prevent this form happening
additions of deoxidisers are made to the CO 2 welding wire to lock up
the oxygen. Most CO2 welding wires are therefore added with silicon
and manganese. The silicon and manganese remove the oxygen as
a slag, which floats to the surface of the weld. Some wires also
contain small additions of other deoxidisers such as aluminum,

titanium and zirconium.
Solid wires for CO2 welding are commonly available in
diameters of 0.8, 1.0, 1.2 and 1.6mm. The choice of wire diameter for
a particular application is extremely important since this decides the
current range, which can be used, and the ease with which the
welder can control the weld pool. The most commonly used wire
sizes are:
0.8mm for sheet steel. This allows low current to be used.
1.2 mm wire for thicker material. This diameter is versatile since, at
low wire speeds, it can be used down to 80A for the welding of sheet
metal or the positional welding, Where as at higher wire speeds
currents up to350A can be used to give high metal deposition rates
and deep penetration.
6. Storage, Quality of CO2 gas :
CO2 gas is supplied in cylinders at a high pressure (140
kg/cm2). When the cylinder is full, nearly 90% of the volume is filled
with CO2 liquid and balance is filled with gas. The CO 2 gas and liquid
phases are in equilibrium pressure. Two type of CO 2 cylinders are
available viz : Gas type and Syphonic type. In gas type cylinders
gaseous CO2 is withdrawn when the cylinder valve is opened. The
physical properties Of CO2 are such that if the gas is taken off too fast
the CO2 gas in the cylinder, cylinder will freeze
and pressure within
the cylinder
as the temperature
drop rapidly. Where CO 2
requirements are in excess of 20I/min the use of syphon cylinder is

recommended. These are fitted with an internal dip tube and CO 2 is
withdrawn as liquid, which must then be passed through a vaporiser
unit with sufficient capacity to suit the rate of draw off required. All
CO2 cylinders must also be fitted with a heater near the gas regulator
to avoid freezing around the regulator. The quality of the CO 2 gas

used for welding must conform to BS4105:1967 or IS 307:1996. As
per the above standard the moisture in the CO 2 gas should be less
than 10 ppm.
7. Weld Defects in CO2 welding :

7.1 Porosity :
Porosity in CO2 welding may be caused by inadequate shielding
gas coverage, gas contamination, electrode contamination, work
piece contamination, too high arc voltage and excess stand off
distance. To ensure adequate shielding gas supply, eliminate any
leaks in the gas line, eliminate drafts blowing into the welding arc
and set required gas flow rate of 20Ipm. Also ensure that the preheater is in place and working. Use only welding grade CO 2 gas.
Use only clean and dry electrode wire. Remove all grease, oil,
rust, paint and dirt from work surface before welding. Set
appropriate voltage and stand off distance.
7.2 Weld metal cracking :
This problem can occur during butt welding of thick plate. The
deep penetration characteristics of CO 2 welding can result in a bead
width to depth ratio of less than one and excessive solidification
strains are imposed on a thin plane of weakness at the center of the
weld. Cracks of this nature are formed only with free flight transfer
which occurs at high currents. The remedy is to use a bead shape
with width to depth ratio greater than 1.2 which is obtained by
adjusting the arc voltage with current.
7.3 Lack of fushion
Some areas of the joint instead of being melted by the high
temperature arc, being melted by the high temperature arc, becomes
only wetted with liquid metal so that the fusion is incomplete. Lack of
fusion can be caused by insufficient heat input, too large weld puddle,
improper joint design and improper welding technique. To increase
the heat input, increase the current and arc voltage. Also reduce the
stand off distance. To avoid large weld pool reduce the weaving width
and increase the travel speed. Use groove angle large enough to
allow access to bottom of the groove. When using a weaving
technique, dwell momentarily on the sidewalls of the groove.
Particularly keep the electrode directed at the leading edge of the
weld puddle.
7.4. Lack of penetration:
Failure to achieve the desired depth of melting is termed as
lack of penetration. In CO2 welding lack of penetration may be caused
by improper joint preparation, improper welding technique and
inadequate welding current. The joint design must provide proper
access to the bottom of the
groove while maintaining proper
electrode extension. Maintain electrode angle normal to work surface
to achieve maximum penetration. Increase the wire feed speed to
increase the current.
7.5 Under cutting :
The groove or unfilled areas alongside the weld fusion zone is called
under cutting and it is causedby welding at a speed too high for the
welding current used. This can be avoided by reducing welding speed
and welding current.
7.6 Spatter :
During C02 welding small particles termed spatter are ejected
from the weld area, which fall on the work, gas nozzle or current
contact tube. Spattering can occur both during dip and free flight
transfer welding and they require different corrective actions. In dip
transfer welding the spatter loss could be minimized by proper
selection of the inductance and arc voltage for the current being
used. When the free flight transfer is used buried arc technique
should be adopted to reduce the spatter loss. However, to enable
easy cleaning of the spatter from the nozzle, silicon spray should be
frequently applied to the welding gun.
8.0 Applications :
C02 welding is extremely useful for joining thin sheets of
thickness range 1.0 to 2.0 mm because it is possible to keep the heat
input low to avoid excessive melting and yet ensure adequate fusion.
This is achieved by selecting a combination of wire diameter, current
and arc voltage which allows the use of a stable short circuiting are.
Butt, lap and fillet joints can be made successfully in all positions.
Butt welds can be made with or without backing. For unbacked joints
up to 1.2 mm thick, close butted joints are preferred. For thicker
sheets from 1.2 to 3.0 mm, a root gap of 0 to 1 mm is preferred
depending on position and sheet thickness.
The C02 free flight or open are welding with a deposition rate of
4 to7 kg/h is well suited for welding of steel plates of thickness 6 mm
or greater. Horizontal-vertical fillets upto 6mm leg length can be made
in one pass and square butt welds in plate upto 6mm can be welded
with one pass either side. For single or double sided welds of 6mm
thickness and upwards a suitable joint preparation is recommended.
C02 welding is also extensively used for welding of wide range of pipe
sizes and applications such as Process pipe work and oil/gas
pipelines.

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CO2 WELDING

2.2 Wire Feeding Unit :

4. Metal Transfer in CO2 welding.

5. Electrode wire for CO2 welding:

contain small additions of other deoxidisers such as aluminum,

drop rapidly. Where CO 2

requirements are in excess of 20I/min the use of syphon cylinder is

to avoid freezing around the regulator. The quality of the CO 2 gas

7. Weld Defects in CO2 welding :

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