Introduction To Gas Shielded Arc Welding

SFI / IWE 1.
06
Introduction to Gas Shielded Arc Welding Page 1
Chapter 1.06: Introduction to Gas Shielded Arc Welding
Contents
1 Classification of gas-shielded welding processes ................................................................ 3

1.1 Gas-shielded metal arc welding (MIG/MAG) ........................................................................ 3
1.2 Tungsten Inert Gas Welding (TIG) ........................................................................................ 4
1.3 Plasma gas-shielded metal arc welding (Plasma MIG/MAG welding) ............................... 5
1.4 Tungsten Plasma welding ......................................................................................................... 5
2 Shielding gases ............................................................................................................................ 6
2.1 Requirements for shielding gases ......................................................................................... 6
2.2 Properties of shielding gases ................................................................................................. 7
2.3 Heat conductivity of shielding gases and gas constituents ................................................. 8
2.4 Classification and designation of shielding gases to DIN EN ISO 14175 .......................... 8
2.5 Purities and dew point .......................................................................................................... 10
3 Examples of classification and designation of shielding gases to
DIN EN ISO 14175 ....................................................................................................................... 10
3.1 Examples of classification .................................................................................................... 10
3.2 Examples of designations .................................................................................................... 11
4 Choice of Shielding Gases ....................................................................................................... 11
4.1 Active shielding gases for MAG- welding of steel .............................................................. 11
4.1.1 Argon-/CO2-mixtures ................................................................................................. 12
4.1.2 Argon-/O2-mixtures .................................................................................................... 12
4.1.3 Argon-/CO2 -/O2 –mixtures ....................................................................................... 12
4.1.4 Carbon dioxide (CO2) ................................................................................................ 12
4.2 Inert shielding gases for TIG welding .................................................................................. 13
4.2.1 Argon .......................................................................................................................... 13
4.2.2 Helium, Argon/helium- mixtures ............................................................................... 13
4.2.3 Argon/hydrogen- mixtures ........................................................................................ 13
4.2.4 Argon of high purity (4.8 minimum).......................................................................... 13
4.3 Inert shielding gases for MIG-welding ................................................................................. 13
4.3.1 Argon .......................................................................................................................... 13
4.3.2 Helium......................................................................................................................... 14
4.3.3 Argon/Helium-mixtures ............................................................................................. 14
5 Shielding gases and gas-mixtures in dependence of the welding process and base
material ......................................................................................................................................... 14
6 Shielding gas consumption and measuring ......................................................................... 15
6.1 Gas flow consumption setting ................................................................................................. 15
6.1.1 Flow rate measuring/setting via a flow-orifice ......................................................... 15
6.1.2 Flow rate setting via a floating device ..................................................................... 15
Welding processes and

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7 Fabrication, transport and storage of shielding gases ...................................................... 16

7.1 Storage of shielding gases in gas cylinders ....................................................................... 17
7.2 Liquefied gases ..................................................................................................................... 17
8 Factory supply of shielding gases.......................................................................................... 17
9 Safety measurements for handling, transport and application of shielding gases ...... 18
9.1 Handling of (high) gas cylinders .......................................................................................... 18
9.2 Colour identification of gas cylinders (DIN EN 1089) ................................................................ 18
9.3 Hazardous goods sticker ...................................................................................................... 19
10 Bibliography ................................................................................................................................ 20
11 Questions ..................................................................................................................................... 21

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1 Classification of gas-shielded welding processes
The term 'gas shielded welding' covers all arc welding processes in which the consumable filler material
or non-consumable electrode and weld pool are protected from the degrading influences of the ambient
air by an added shielding gas. These gas shielded welding processes have been classified into two main
groups according to the melting behaviour of the electrode.
 Gas-shielded Metal Arc Welding (MIG/ MAG welding), having a consumable electrode
 Gas-shielded Tungsten Arc Welding (TIG welding), having a non-consumable electrode
A more detailed classification is shown in figure 1.
Gas-shielded Arc Welding
Gas-shielded Gas-shielded
Metal Tungsten
Arc Welding Arc Welding
Metal Inert Metal Active TIG

MIG MAG
Gas Welding Gas Welding Tungsten Plasma
Metal Inert Metal Active
with flux with flux Inert Gas Welding
Gas Welding Gas Welding
cored wire cored wire Welding
Plasma metal MAG-M Plasma Plasma Jet- Powder

Electric Gas MAG-C Plasma Arc
gas-shielded Gas mixture Beam Arc Plasma
Welding welding
CO2-welding Welding
welding welding Welding Welding
Figure 1: Classification of gas shielded welding processes /2/
1.1 Gas-shielded metal arc welding (MIG/MAG)
For gas-shielded metal arc welding the following process variables have been differentiated for Metal
Inert Gas Welding (MIG) and Metal Active Gas Welding (MAG).
Process numbers according to DIN EN ISO 4063
Metal-active gas welding with solid wire 135

Metal-active gas welding with flux cored wire 136
Metal-active gas welding with metal cored wire 138
Metal-inert gas welding with solid wire 131
The heat-source for welding is an ignited arc between the base metal and the continuous filler metal
electrode. In order to protect the melt pool from the degrading influences of the surrounding air a
shielding gas is required.
For MIG-welding of non-ferrous materials argon, helium or mixtures of both are being used. For MAG-
welding active shielding gas is being used for metallurgical or technical reasons. For welding of un-
alloyed, low-alloyed and high-alloyed steels active shielding gases are used like CO2 (MAG-C), Argon-
CO2-mixtures, Argon-Oxygen-mixtures and more component-mixture- gases (MAG-M).

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Wire electrode
Wire feeder
guiding rolls
Shielding gas Contact tube
Shielding gas
nozzle
Power
supply
Weld
Arc
Workpiece
Figure 2: Principle of metal gas shielded welding works
1.2 Tungsten Inert Gas Welding (TIG)
The heat-source for welding is an ignited arc between the base metal and a non-melting tungsten
electrode. The filler material is added manually into the arc where it is melted. The heated tungsten
electrode, the melt pool and the surrounding area are protected by the shielding gas from the
surrounding air. Shielding gases like Argon, Helium or mixtures from both and for specific base materials
also Argon-Hydrogen-mixtures are being used.
The thermal capacity of the Tungsten electrode is limited. This sets restrictions to the deposition rates
and the welding speed but on the other hand this enables a precise weld-layout even with an imprecise
weld preparation.
Process numbers according to DIN EN ISO 4063
Tungsten-inert-gas welding with solid wire or rod 141

Tungsten-inert-gas welding without filler wire or rod 142
Tungsten-inert-gas welding with flux cored wire or rod 143
Tungsten-inert-gas welding with solid wire or rod with deoxidizing gas (partly) 145
Tungsten electrode
Contact tube
Shielding gas
Shielding gas
nozzle
Power
supply
Filler
material
Workpiece Arc
Figure 3: Tungsten inert gas welding (TIG)

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1.3 Plasma gas-shielded metal arc welding (Plasma MIG/MAG welding)
This process is a combination of gas-shielded metal arc welding (MIG/MAG) and plasma welding. At the
beginning of the weld the annular plasma-arc is heating the base material before the continuous filler
material is being added. Two independent power sources are used; one with the constant current char-
acteristic curve (Plasma power source) and the other one with a constant voltage characteristic curve
(MIG/MAG power source)
Plasma (focussing) gas Plasma gas

Shielding Cooling water
gas
Impuls generator
Plasma Constant
Power supply Voltage
Power supply
Figure 4: Plasma MIG/MAG welding
1.4 Tungsten Plasma welding
The arc is located between the tungsten electrode and either a water-cooled copper-nozzle (non-
transferred-mode) or a base material (transferred-mode) located in a gaseous atmosphere. This copper-
nozzle (orifice-nozzle) is constricting the arc and increases the density-capacity.
Tungsten electrode
Cooling water
Shielding gas
Plasma gas
Orifice nozzle
Plasma nozzle
Figure 5: Tungsten Plasma welding.

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2 Shielding gases
During gas-shielded arc welding it is essential to protect the weld pool from the degrading influences of
the air. Without this protection the weld pool would be mainly contaminated with nitrogen- and oxygen
inclusions and embrittlement of the weld metal would become evident.
Shielding gases protect the weld pool, the melting filler material and the non-consumable tungsten
electrode, principally against the effects of the air.
2.1 Requirements for shielding gases
Active shielding gases are gases which cause the arc to interact chemically and physically with the filler
and base material.
Inert shielding gases are gases which do not enter into chemical reactions during welding.
Shielding gases for welding and cutting differ in terms of:
1. how they react during welding (inert, oxidising, slow-reacting, reducing)

2. density (heavier/lighter than air)
3. thermal conductivity and capacity
4. ionisation/dissociation energy and hence in the arc voltage, in relation to a given arc length (arc curve)
5. boiling point
Summary of requirements for shielding gases
General requirements:
– Suitability for all types of arcs

– Sufficient shielding effect depending on place of use and type of weld
– Favourable melt flow characteristics
– Not sensitive to impurities in the weld seam area
– Can be used for all wire diameters
– Slag formation and/or distribution over the weld surface
– Resistance to pore formation
– Prevention of weld spatter
Physical requirements:
– Ignition behaviour at start of welding

– Arc stability, i.e. constant arc
– Arc shorting out and re-igniting
– Plasma formation/electrical conductivity
– Dissolution characteristics depending on the material
– Degassing characteristics
Thermal requirements:
– Heat conductivity
– Heat capacity
– Heat transfer capacity, i.e. heat transfer coefficient

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Metallurgical requirements:
– Element pick-up
– Element burn-off
– Preservation of mechanical-topological characteristics
– Preservation of corrosion-resistance characteristics
2.2 Properties of shielding gases
Which gases or gas mixtures are suitable for shielding gases depends mainly on the type of base
material. Many of the base material groups can be welded with different types of shielding gases so that
many relationships have to be considered before making a choice of shielded gas.
Shielding gases are standardized in DIN EN ISO 14175. In this standard the most common, for practical
use, shielding gases are listed according to their chemical behaviour and composition.
Table 1: Gas characteristics to DIN EN ISO 14175

Specific characteristics
at 0 °C and 1.013 bar Reaction behaviour
Chem. (0.101 MPa) during welding
Gas
symbol (s) Density
Relative Boiling
(air = 1.293)
density to air point [°C]
[kg/m³]
Argon Ar 1.784 1.380 - 185.9 Inert
Helium He 0.178 0.138 - 268.9 Inert
1)
Carbon dioxide CO2 1.977 1.529 - 75.5 Oxidising
Oxygen O2 1.429 1.105 - 183.0 Oxidising
2)
Nitrogen N2 1.251 0.968 - 195.8 Slow-reacting
Hydrogen H2 0.090 0.070 - 252.8 Reducing
1)
Sublimation temperature
2)
Nitrogen behaves differently with different materials, and the effects may be adverse.
The huge difference in the density of Argon and Helium is being reflected to the required flow quantity. In
case helium- or helium holding shielding gases are used the actual gas flow quantity must be increased
by 2 or 3 times when using an argon reducer. Based upon these density differences between Argon and
Helium correction factors have to be considered for making settings of argon calibrated pressure reduc-
ers.
Table 2: Density and correction factor depending on the helium part in argon based shielding gases
Gas, / gas mixtures Density Correction factor
At 15°C, 1 bar flow-reading
3
[kg/m ] multiplied with
100% Argon 1,78 1,00
75% Ar + 25% He 1,29 1,14
50% Ar + 50% He 0,92 1,35
25% Ar + 75% He 0,54 1,75
100% He 0,17 3,16
Example: Helium- Argon mixture

Gas Flow-reading Correction factor Actual gas flow
25% Ar + 75% He 12 l/min 1,75 21 l/min

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2.3 Heat conductivity of shielding gases and gas constituents
Figure 6: Heat conductivity of shielded gas constituents (according to Linde)
The heat conductivity of the shielding gas affects how the weld seam is formed, the weld pool
temperature, weld pool degassing and welding speed. During MIG and TIG welding of aluminium
materials, the welding speed and weld penetration behaviour with can be increased considerably by
adding helium or, during TIG welding austenitic of austenitic steels, steels by adding hydrogen.
Chemical characteristics influence the metallurgical behaviour and the weld seam surface. For example,
oxygen and carbon dioxide for example, lead to the burning off of alloy elements and low viscosity of the
weld pool; both gases are oxidants. Hydrogen is a reducing gas; argon and helium do not react with
metals, as they are inert.
2.4 Classification and designation of shielding gases to DIN EN ISO 14175
Gases and gas mixtures are classified by the number in accordance with the above international
standard, followed by the symbol for the gas as in Table 3
NOTE: This classification is based on the reaction behaviour of the gas or gas mixture.
Main group:
The letters and numbers used for the main group are as follows:
— I: inert gases and gas mixtures;

— M1, M2 and M3: oxidising gas mixtures with oxygen and/or carbon dioxide;
— C: highly oxidising gases and gas mixtures;
— R: reducing gas mixtures;
— N: slow-reacting gas or gas mixture with nitrogen;
— O: oxygen;
— Z: gas mixtures with constituents which are not included in Table 3 or gas mixtures
whose compositions are outside the ranges stated in Table 3.

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Sub-group
The main groups apart from Z are divided into sub-groups, depending on the presence and content of
certain constituents which affect the reaction (see Table ). The values stated in Table 3 are nominal
values.
Table 3: Classification of process gases for welding joints and related processes
Symbol Constituents in percent by volume (nominal)
Main Sub- oxidising inert Reducing Low reactivity

group group CO2 O2 Ar He H2 N2
I 1 100
2 100
3 Rest 0.5 ≤ He ≤ 95
M1 1 0.5 ≤ CO2 ≤ 5 Resta 0.5 ≤ H2 ≤ 5
a
2 0.5 ≤ CO2 ≤ 5 Rest
3 0.5 ≤ O2 ≤ 3 Resta
4 0.5 ≤ CO2 ≤ 5 0.5 ≤ O2 ≤ 3 Resta
M2 0 5 < CO2 ≤ 15 Resta
1 15 < CO2 ≤ 25 Resta
2 3 < O2 ≤ 10 Resta
3 0.5 ≤ CO2 ≤ 5 3 < O2 ≤ 10 Resta
4 5 < CO2 ≤ 15 0.5 ≤ O2 ≤ 3 Resta
5 5 < CO2 ≤ 15 3 < O2 ≤ 10 Resta
6 15 < CO2 ≤ 25 0.5 ≤ O2 ≤ 3 Resta
7 15 < CO2 ≤ 25 3 < O2 ≤ 10 Resta
M3 1 25 < CO2 ≤ 50 Resta
2 10 < O2 ≤ 15 Resta
3 25 < CO2 ≤ 50 2 < O2 ≤ 10 Resta
4 5 < CO2 ≤ 25 10 < O2 ≤ 15 Resta
5 25 < CO2 ≤ 50 10 < O2 ≤ 15 Resta
C 1 100
2 Rest 0.5 ≤ O2 ≤ 30
R 1 Resta 0.5 ≤ H2 ≤ 15
a
2 Rest 15 < H2 ≤ 50
N 1 100
a
2 Rest 0.5 ≤ N2 ≤ 5
a
3 Rest 5 < N2 ≤ 50
4 Resta 0.5 ≤ H2 ≤ 10 0.5 ≤ N2 ≤ 5
5 0.5 ≤ H2 ≤ 50 Rest
O 1 100
Gas mixtures with constituents which are not included in the table or gas mixtures whose compositions are
Z
outside the ranges indicated.b
a For the purpose of this classification, argon may be substituted partially or completely with helium.
b Two gas mixtures with the same Z classification must not be interchanged.

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2.5 Purities and dew point
The purity and dew point of the gas constituents and gas mixtures must meet the requirements specified in
Table 2. Moisture content can be expressed either as a concentration in ppm (parts per million) or as the
dew point at 0.101 MPa in °C.
Purities and moisture contents of specific gas mixtures are not covered in the standard DIN EN ISO
14175.
Table 2: Minimum requirements for purities and moisture contents of gases and gas mixtures
Moisture
Purity Dew point at
content
Vol.% 0.101 MPa
Main group/gas (volumes)
ppm
minimum °C
maximum
I Inert 99.99 −50 40
a
M1 Gas mixture 99.9 −50 40
a
M2 Gas Mixture 99.9 −44 80
a
M3 Gas Mixture 99.9 −40 120
a
C Carbon dioxide 99.8 −40 120
R Reducing 99.95 −50 40
N Nitrogen 99.9 −50 40
O Oxygen 99.5 −50 40
IMPORTANT, please note: a higher purity and/or lower dew point may
be advisable for certain applications to avoid potential oxidisation and
contamination.
a
Nitrogen: max. 1,000 ppm
Note: on the market the purity of gases is generally indicated by number codes. For example, Argon with
a purity of 99,996% is indicated by Argon 4.6.
3 Examples of classification and designation of shielding gases to DIN EN ISO 14175

3.1 Examples of classification
Number of this international standard, followed by the symbol for the gas or gas mixture (main group and
sub-group)
EXAMPLE 1 Gas mixture with 6% carbon dioxide, 4% oxygen, the rest argon
Classification: ISO 14175 – M25
EXAMPLE 2 Gas mixture with 30% helium and the rest argon:
Classification: ISO 14175 – I3
EXAMPLE 3 Gas mixture with 5% hydrogen and the rest argon:

Classification: ISO 14175 – R1
EXAMPLE 4 Gas mixture with 0.05% oxygen and the rest argon:
Classification: ISO 14175 – Z

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3.2 Examples of designations
The base gas symbol must be followed by the symbols for the other constituents in decreasing order of
percentage content followed by the values for the nominal composition in per cent by volume, separated
by a dash.
EXAMPLE 1 Gas mixture with 6% carbon dioxide, 4% oxygen and rest argon
Designation: ISO 14175 – M25 – ArCO – 6/4
EXAMPLE 2 Gas mixture with 30% helium and rest argon:

Classification: ISO 14175 – I3
Designation: ISO 14175 – I3 – ArHe – 30
EXAMPLE 3 Gas mixture with 5% hydrogen and rest argon:

Classification: ISO 14175 – R1
Designation: ISO 14175 – R1 – ArH – 5
EXAMPLE 4 Gas mixture with 7.5% argon, 2.5% carbon dioxide and the rest helium:
Designation: ISO 14175 – M12 – HeArC – 7.5/2.5
For gas mixtures with constituents listed in Table 3 but whose contents are outside the ranges stated,
the base gas symbol must be preceded by the letter Z. This is followed by the symbols for the
components as stated above, followed by the values for the nominal composition in percentage by
volume, separated by a forward slash.
EXAMPLE 5 Gas mixture with 0.05% oxygen and rest argon:

Denomination: ISO 14175 – Z – ArO – 0.05
For gas mixtures with constituents which are not listed in Table 3, the base gas symbol must be
preceded by the letter Z. This is followed by the symbols for the constituents as stated above, but with a
plus sign before the constituents not listed, followed by the values for the nominal composition in per
cent by volume, separated by a dash.
EXAMPLE 6 Gas mixture with 0.05% xenon, chemical symbol Xe, rest argon:
Designation: ISO 14175 – Z – Ar+Xe – 0.05
4 Choice of Shielding Gases
4.1 Active shielding gases for MAG- welding of steel
Shielding gases which are reacting with the melting filler wire and the weld pool are designated as active
shielding gases (Metal Active-Gas welding). CO2 or O2 and/or CO2 portions in
Active shielding gases consists CO2 or for mixture gases with high argon content, components of O2
and/or CO2. The chemical behaviour of oxygen-emitting shielding gases is called “oxidising” which are
mainly used for welding of steel. Compared to welding with pure argon, welding of steel with oxidising,
argon-rich shielding gases and pure CO2 creates fewer pores, less undercut and a more stable arc.

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4.1.1 Argon-/CO2-mixtures
For un-alloyed and low-alloyed steels Ar/CO2-mixtures are used with CO2-portions of 4 – 25% (common
used shielding gas: 82% Ar + 18% CO2). This shielding gas type is suitable for welding solid wires and
most of the flux cored wires. Compared to pure Argon with an increasing CO2 percentage the side
penetration becomes more, less pores-intensity and a bigger slag quantity is created. For welding in the
short-arc mode Ar/CO2 mixtures are suitable for welding thin sheet metals and gap bridging.
For welding in spray-arc mode only a restricted percentage of CO2 is possible. With percentages of 20%
of more even at high arc-intensities short-circuit situations are occurring during the drop transfer. Even
during pulsed-welding the drop-transfer is becoming more difficult with increasing CO2 percentages and
therefore the CO2-percentage is limited to 20%
For welding of high-alloyed, austenitic CrNi-steels the C O2 percentage is limited to 5% in order to
prevent Cr-depletation at the grain borders and the corresponding intergranular corrosion. In this
situation an argon-rich mixture gas with 2.5% C O2 is common.
4.1.2 Argon-/O2-mixtures
Oxygen percentages of 1 – 12% are being used for welding of steels. Compared to pure argon a higher
side penetration and a more stable arc are achieved. With increasing oxygen percentages the surface
tension of the weld pool is lowered which enables, especially in the flat welding position, more smoother
and flat weld seams. For welding in the short-circuit-arc mode Ar/Oxygen-mixtures are very suitable and
in the spray- and pulsed mode welding it creates a very stable arc. The spray arc range already starts at
lower arc-intensities.
4.1.3 Argon-/CO2 -/O2 –mixtures
Common mixtures are Argon with 3-8% O2 and 5-15% C O2. These mixtures are suitable for welding un-
alloyed and low-alloyed steels. In the short-circuit-arc mode it is most convenient for welding thin sheet
metal and gap-bridging. In the spray-arc mode the drop transfer volume is small and less spatter.
4.1.4 Carbon dioxide (CO2)
CO2 is mainly used for welding un-alloyed steel. The CO2 arc is, next to metal-vapours, mainly
influenced by the heat conductivity of the gas. CO2 conducts/ transfers the heat very well so that under
similar current-intensity conditions the voltage-setting is about 4 volts higher. The penetration profile
under similar arc conditions is significantly wider compared to argon-rich mixtures. The out-of-position
welding is improved, for example welding down of thick components.
The drop transfer is even at higher arc-intensities not free of short-circuit situations. The forces of the arc
and the short-circuit conditions are making the drop transfer more difficult which creates a more
increased spatter and the weld pool is placed into a swinging motion. This results in a coarser weld
seam appearance. When welding with CO2 mixtures the setting of the arc-voltage and the current
intensity has to be done more accurate compared to mixture gases. The welder requires a certain
experience for setting the working point. The use of an adjustable inductance is to be preferred to limit
the short-circuit-current-peaks during the drop transfer. Welding of thin sheet metals (<1mm) and gap-
bridging becomes very difficult with CO2.
A pulsed controlled drop transfer with pure CO2 is not possible because to high backward pointed forces
are initiated at the wire end. Welding with CO2 creates relatively much slag. At higher arc-intensities
undercuts filled with slag could arise. The pores avoidance is good.

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4.2 Inert shielding gases for TIG welding
In contradiction to MAG welding only inert gases can be used for TIG welding. Oxidising elements, even
at minimum quantity levels, would destroy the tungsten electrode during TIG welding.
4.2.1 Argon
Argon is the most used shielding gas for TIG welding resulting from the following:
Good protection level due to high density.

Good ignition characteristics due to low ionisation-voltage requirements.
Stable arc conditions, even with alternating current
Good ignition properties
4.2.2 Helium, Argon/helium- mixtures
Using helium or argon-helium mixtures creates a higher arc-temperature due to the higher arc-voltage
under similar current intensity. Furthermore better penetration- and welding-speed ratios can be
achieved. Disadvantages are the less favourable ignition behaviour, the lower density and the less stable
arc at lower current-settings.
4.2.3 Argon/hydrogen- mixtures
Also by using argon-hydrogen mixtures the energy balance of the arc can be improved. Additionally the
reducing effect of the hydrogen is being used. The application for these mixtures is limited for the
welding of austenitic CrNi-, Ni- and Ni-alloyed steels.
4.2.4 Argon of high purity (4.8 minimum)
For welding of specific tasks, for example the welding of Titanium, additional to the use of Argon 4.8
(minimum) a secondary shielding gas protection (trailing-shield) is required. This trailing shield protects
the solidified weld pool and the heat-affected-zone from getting oxidised until the moment of sufficient
cooling down.
4.3 Inert shielding gases for MIG-welding
4.3.1 Argon
Argon can be very well ionised although the heat conductivity is less. The argon-arc tends to fast
moving, widely-spread arc-spots on work pieces with a low oxidised surface.
Due to this phenomenon even at higher arc-intensities lower side penetration characteristics occur. The
finger-shaped penetration in the weld middle at high current-settings occurs, in the presence of limited
metal vapour components, mainly by the concentrated material transfer and the high gas flow in the arc-
centre-zone.
Short-circuit mode welding is possible but creates often lack of fusion in materials with good heat
conductivity. Spray- and pulse-mode welding is well adjustable.
For steel pure argon will not be used because argon-mixed shielding gases have a more stable arc-
behaviour, a better penetration profile, more flat weld seams, less pores and less undercuts.

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4.3.2 Helium
Helium has a good heat conductivity which is positive for the penetration-profile. When using helium or
mixtures gases with higher helium content often the preheating of thick components with high heat
conductivity can be skipped. The pores avoidance is good.
Due to the high prices and the very unstable arc-behaviour solely helium as shielding gas is seldom
used. Helium is lighter as the surrounding air creating the tendency to ascend upwards which results in a
higher gas-flow rate. For achieving a similar protection level compared to Argon, the flow intensity has to
be increased by a factor 3.
4.3.3 Argon/Helium-mixtures
For welding MIG welding of aluminium and aluminium alloys next to argon more often argon-helium
mixtures are being used. The helium content makes the arc energy-richer. A deeper and wider
penetration is achieved compared to argon. A further advantage is the even better pores avoidance.
5 Shielding gases and gas-mixtures in dependence of the welding process and base
material
For an optimal use of the different properties and influences of the shielding gases it is required to
choose the shielding gas or mixture in dependency of the welding process and base material.
Table 5: Shielding gases for TIG welding in dependency of the base material
Base material Shielding gas Root shielding gas
Non-alloyed and low-alloyed steels Argon N2 90% + H2 10%
Argon Argon
Austenitic CrNi-Steels Ar 98% + H2 2% N2 90% + H2 10%
Ar 95% + H2 5% Ar 90% + H2 10%
high alloyed corrosion-, acid- and heat resistance Argon
steels, creep- and low-temperature resistance Argon N2 90% + H2 10%
steels Ar 90% + H2 10%
Aluminium, Al-alloys Argon 100%
Copper- and Cu-alloys, Ar 75% + He 25%
Nickel and Ni-alloys Ar 50% + He 50% Argon
Ar 25% + He 75%
Helium
Gas-sensitive alloys like Titanium, Tantalum etc. Argon with purity > 4.8 Argon with purity > 4.8
Duplex- und Super-Duplex-Steels Argon Argon
Ar + N2 ≤ 5%

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Table 6: Shielding gases for MIG/MAG welding in dependency of the base material
Base material MIG MAG Root shielding gas
Non-alloyed and low-alloyed steels Ar 92% + O2 8%
Ar 82% + CO2 18%
Ar 90% + CO2 5% + O2 5%
Ar 82% + CO2 14% + O2 4%
CO2 100%
high alloyed corrosion-, acid- and heat Ar 97% + O2 3% Argon
resistance steels, creep- and low- Ar 98 % + CO2 2% N2 90% + H2 10%
temperature resistance steels Ar 69% + He 30% + O2 1% Ar 90% + H2 10%
Aluminium, Al-alloys Argon 100% Argon

Copper- and Cu-alloys Ar 50% + He 50%
Nickel and Ni-alloys Argon 100% Argon
Gas-sensitive alloys like Titanium, Tanta- Argon with purity ≥ Argon with purity ≥ 4.8
lum etc. 4.8
6 Shielding gas consumption and measuring
The shielding gas consumption (shielding gas flow) is determined by a number of factors, as follows:
 the welding process and weld pool size

 the electrode size (diameter) with MIG/MAG welding
 gas type and composition
 size of welding torch/gas nozzle
As a guidance/setting value the shielding gas flow for MAG welding can be calculated via the formula:
wire-diameter-size x 10-12.
Example: wire diameter=1.2mm  glas flow rate: 14 l/min.
For TIG welding the gas-flow setting can be achieved from the gas nozzle inside diameter: with a gass
nozzle inside diameter of 8mm a gas flow rate of 8 l/min is required.
6.1 Gas flow consumption setting
In order to reduce the cylinder pressure, nowadays often set to 300 bar, it is required to use a pressure
reducer which sets the gas to the desired pressure and enables a suitable gas-flow rate for the specific
weld job.
6.1.1 Flow rate measuring/setting via a flow-orifice
In the shielding gas supply line a calibrated orifice with a defined flow cross-section is integrated which
sets the flow rate in dependency of the gas pressure. With the pressure adjustment screw the required
gas pressure is set after which the gas flow manometer is showing the flow-rate.
6.1.2 Flow rate setting via a floating device
The pressure is set constantly. By turning the adjustment screw the flow-cross-section, respectively the
gas-flow rate will be changed. The flowing gas is lifting the floating device (ball) accordingly to the flow-
rate. The flow-rate value is to be read from the top of the ball.

equipment
SFI / IWE 1.06
1 Bottle pressure manometer

1 Bottle pressure manometer
2 Gas flow manometer
2 Flow tube with floating device
3 Pressure adjustment screw
3 Adjustment screw
4 Shut-off valve Type of gas
4
5 Calibrated orifice
6 Type of gas
Figure 7: Shielding gas flow setting and measuring device
7 Fabrication, transport and storage of shielding gases
Argon, nitrogen, oxygen and inert gases are produced mainly by liquefying air in modern air separation
plants. Helium is an exception which comes from natural gas sources in the USA, and is therefore
cheaper to produce there than separating it from the surrounding air having a helium content of
0.00052%.
For liquefying the air, temperatures near to minus 200 °C are required. For the following separation of
the different components each critical temperature point is successively being used
Fabrication
The six basic shielding gases are manufactured differently
Argon, nitrogen and oxygen are manufactured by liquefying

air, consisting 78%N2, 21%O2 and 1% nobelgases, in large air
separation plants.
For the separation of liquefied air into it’s components, the
different critical temperature points are being used.
Helium is just for a very small part available in the air and is
being produced more economically from earth-gas-sources in the
USA and East-Europe.
The in the market used carbon dioxide (CO2) is mainly being

extracted from natural resources in Germany. A part is also
extracted out of the Chemical Industry
Natural hydrogen (H2) is mainly enclosed in water and can be

extracted out if with a huge energy input by electrolysing.
The in the market available quantities are mainly produced via the
chlorine-alkaline-electrolyse process in which the chlorine and
caustic soda are manufactured from a watery saline solution. Schematic representation of a separation unit
Figure 8: Surrounding air separation unit

equipment
SFI / IWE 1.06
7.1 Storage of shielding gases in gas cylinders
Oxygen, argon, nitrogen and hydrogen are gases which are in gaseous form at ambient temperature and
pressure, and are supplied mainly in steel cylinders. The maximum permitted pressures are 150 or 200
bar, the latest cylinders have 300 bar. The actual pressure can fluctuate from the given pressures and
even depends on the surrounding temperature.
Carbon dioxide, CO2 liquefies at around 54 bar and + 15 °C. In a cylinder full of liquefied gas, the gas is
liquefied completely except for a small gas cushion.
Table 7: Storage of gases

Argon, helium, gas mixtures: gaseous
Cylinder capacity in l 10 20 50/50
Filling pressure in bar 200 200 200/300
Gas content in m³ 2 4 10/15
Carbon dioxide: liquid

Cylinder capacity in kg 10 20 30
Content in l 13 26 40
Gas content in m³ 5 11 16
If larger amounts are removed, icing may occur. For liquefied gases like CO2, the use of a pre-heater in
front of the pressure reducer is preferred.
7.2 Liquefied gases
Liquid gases are supplied in insulated tanks at suitably low temperatures. Carbon dioxide is supplied in
cylinders in liquid form at ambient temperature. Liquid gases must be converted to their gaseous state
before using.
In order to produce gas mixtures, the liquid gas constituents must be vaporised before mixing. Argon-
oxygen mixtures can also be stored pre-mixed in liquid form, without needing a mixer unit to supply
them.
8 Factory supply of shielding gases
In general the required shielding gases are supplied in separate gas cylinders. But for higher demands
and efficient working the shielding-gas supply comes from cylinder bundles or batteries and a cold
gasification system via a central ring-supply to the specific area. An example is given by figure 9.

equipment
SFI / IWE 1.06
Cold gasification system for Argon
Cylinder bundle
Shielding gas Cylinder battery
Forming gas
Ring supply
Fixture for purging of

Single cylinder supply root pass Cylinder bundle Cylinder battery
Figure 9: Central shielding-gas supply system
9 Safety measurements for handling, transport and application of shielding gases
9.1 Handling of (high) gas cylinders
Gas cylinders have to be transported with care and are not allowed to be thrown or rolled. During
transport or storage the safety caps have to be attached properly. Gas cylinders are to be protected
against any uncontrolled heat- or impact- influences. Vertical stored cylinders have to be secured for
falling down via chains or brackets. In the workshop area only the actual to be used gas cylinders are to
be found. A collecting of gas cylinders should be avoided. The refilling from larger cylinders into smaller
cylinders requires special knowledge and is prohibited for this reason. The gas cylinder storage area
must be ventilated sufficiently. The density of each shielding gas partly differs enormous from the
surrounding air density. Shielding gases which are heavier than the surrounding air are replacing the
breathing air and are a danger for the employees. Hydrogen containing shielding gases can create
dangerous concentrations of detonating hydrogen gas in the surrounding air.
The stamp marking of gas cylinders is according to DIN EN ISO 13769.
On the gas cylinder shoulder for example the following details are marked: the test date, empty weight,
capacity and working pressure.
9.2 Colour identification of gas cylinders (DIN EN 1089)
The colour identification is realised by colouring the cylinder shoulder or the complete cylinder according
to the type of gas. The colour identification is only used as additional information. The only mandatory
identification is defined by hazardous good stickers.

equipment
SFI / IWE 1.06
Remark: until 2006 Actual until 2006 Actual

The gas cylinder can have differ-
ent colours: one is shown in the Nitrogen Hydrogen
picture and the other(s) is men-
Dark green Black red red
tioned between brackets ( ).
Dark green grey (dark red red
green, black)
until 2006 Actual
Oxygen (technical) Carbondioxide Forming gas (Mixture nitrogen / hydro-

gen)
blue white grey grey red red
blue blue (grey) grey grey red grey

(dark green)
Acetylene Helium Mixture Argon/CO2

yellow maroon grey brown grey Bright green
yellow maroon (black, grey grey grey grey

(black) yellow)
Argon Xenon, Krypton, Neon Pressed air

grey Dark green grey Bright green grey Bright green
grey grey grey (black) grey grey grey

(dark green) (bright green)
9.3 Hazardous goods sticker
The hazardous stickers, as shown in figure 11 and 12 meet the transport regulations (GGVS/GGVE).
The new sticker (figure 11) is marked with the warning word “Danger” = “GEFAHR”. Above this the new
symbols are given. On the left side the danger- and safety details (P- and H-marks). On the right side,
additional information.
Figure 11: hazardous goods sticker (new)

equipment
SFI / IWE 1.06
1 Risks and safety information 5 EEC no. for individual substances or the word
2 Hazard labels 'gas mixture'
3 Gas composition of the gas or 6 Full gas details to GGVS
gas mixture 7 Manufacturers' instructions
4 Manufacturer's product name 8 Manufacturers' name, address and telephone no.
Figure 3: Hazardous goods sticker
10 Bibliography
/1/ DIN EN; DIN EN ISO 13769: gas cylinders – stamp marking
DIN Deutsches Institut für Normung e.V.; Berlin; Beuth Verlag GmbH
/2/ DIN EN 14610 welding and allied processes – definitions of metal welding processes
/3/ TRGS 510 Technical regulations for compressed gases
/4/ TRBS 3145 Assembly and storage of gas cylinders / vessels

equipment
SFI / IWE 1.06
11 Questions
(1) Which functions does the shielding gas have for Gas-shielded Metal Arc Welding and Gas-
shielded Tungsten Arc Welding?
 Cooling of the electrode

 Protection of the electrode and the weld pool from the degrading influences of the sur-
rounding air
 Preventing fume initiation
 Cooling of the welding torch, in order to weld with not-water-cooled torches
(2) Which shielding gases are applicable for MAG- welding?
 Argon and Helium

 Nitrogen and hydrogen
 Carbon dioxide and mixture gases
 Krypton and Xenon
(3) For TIG welding only inert gases can be used. Why?
 Active shielding gases destroy the tungsten electrode

 Inert shielding gases improve the penetration profile
 Inert shielding gases are more economical than active shielding gases
 During the application of active shielding gases the creation of pores is initiated.
(4) What means the designation M21 of a shielding gas?
 The shielding gas has a composition of 82% Argon, rest CO2

 The shielding gas has a composition of 82% CO2, rest Argon
 The shielding gas is suitable for the TIG welding of steel
 It´s a mixture gas made of main group M2 and subgroup 1
(5) In which manner is CO2 being stored in gas cylinders?
 Liquid
 Gaseous
 Dissolved
 Solid, by means of dry ice
(6) How are gas cylinders designated permanently
 By means of specific colouring all around the cylinder

 By means of the hazardous sticker
 By stamping of the designation on the cylinder shoulder
 By means of specific colouring on the cylinder shoulder
(7) Which kind of shielding gas supply is more or less the appropriate choice for small and middle
big companies?
 Central shielding gas supply with cold gasifier system

 Central shielding gas supply with cylinder bundle
 Separate cylinder shielding gas supply
 Central shielding gas supply with cylinder battery

equipment

Introduction To Gas Shielded Arc Welding

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SFI / IWE 1.

Chapter 1.06: Introduction to Gas Shielded Arc Welding

1 Classification of gas-shielded welding processes ................................................................ 3

Welding processes and

7 Fabrication, transport and storage of shielding gases ...................................................... 16

Welding processes and

1 Classification of gas-shielded welding processes

A more detailed classification is shown in figure 1.

Gas-shielded Arc Welding

Metal Inert Metal Active TIG

Plasma metal MAG-M Plasma Plasma Jet- Powder

Figure 1: Classification of gas shielded welding processes /2/

1.1 Gas-shielded metal arc welding (MIG/MAG)

Process numbers according to DIN EN ISO 4063

Metal-active gas welding with solid wire 135

Welding processes and

Shielding gas Contact tube

Figure 2: Principle of metal gas shielded welding works

1.2 Tungsten Inert Gas Welding (TIG)

Process numbers according to DIN EN ISO 4063

Tungsten-inert-gas welding with solid wire or rod 141

Figure 3: Tungsten inert gas welding (TIG)

Welding processes and

1.3 Plasma gas-shielded metal arc welding (Plasma MIG/MAG welding)

Plasma (focussing) gas Plasma gas

Figure 4: Plasma MIG/MAG welding

1.4 Tungsten Plasma welding

Figure 5: Tungsten Plasma welding.

Welding processes and

2.1 Requirements for shielding gases

Shielding gases for welding and cutting differ in terms of:

1. how they react during welding (inert, oxidising, slow-reacting, reducing)

Summary of requirements for shielding gases

– Suitability for all types of arcs

– Ignition behaviour at start of welding

Welding processes and

2.2 Properties of shielding gases

Table 1: Gas characteristics to DIN EN ISO 14175

Example: Helium- Argon mixture

Welding processes and

2.3 Heat conductivity of shielding gases and gas constituents

Figure 6: Heat conductivity of shielded gas constituents (according to Linde)

2.4 Classification and designation of shielding gases to DIN EN ISO 14175

— I: inert gases and gas mixtures;

Welding processes and

Main Sub- oxidising inert Reducing Low reactivity

Welding processes and

2.5 Purities and dew point

3 Examples of classification and designation of shielding gases to DIN EN ISO 14175

EXAMPLE 3 Gas mixture with 5% hydrogen and the rest argon:

Welding processes and

3.2 Examples of designations

EXAMPLE 2 Gas mixture with 30% helium and rest argon:

EXAMPLE 3 Gas mixture with 5% hydrogen and rest argon:

EXAMPLE 5 Gas mixture with 0.05% oxygen and rest argon:

4 Choice of Shielding Gases

4.1 Active shielding gases for MAG- welding of steel

Welding processes and

4.1.3 Argon-/CO2 -/O2 –mixtures